Discreet Disposable Absorbent Article

ABSTRACT

Disposable absorbent articles suitable for providing leakage protection for users that experience relatively small to relatively large discharges of fluids wherein the article comprises a chassis which comprises a primary topsheet; a backsheet; an absorbent core having a front end portion, a central portion, and a rear end portion along its length, the core being disposed between the primary topsheet and the backsheet, and the article exhibits an article length of from about 371 mm to about 500 mm according to the Article Length Method; a dry pad thickness of between about 4.6 mm to about 12 mm according to a Pad Thickness Method; and an Energy of Recovery at a load of 30 ml of from about 4 mJ to about 11 mJ according to a Bunch Compression Method.

FIELD

The present invention pertains to discreet disposable absorbent articlessuitable for absorbing and containing body exudates.

BACKGROUND

A variety of disposable absorbent articles have been relied on byconsumers to handle or manage body exudates. These consumers may includebabies, toddlers, children, teenagers, adults, and elderly persons.Thus, it is clear that the types of fluids or body exudates managed bysuch articles may vary as well to include urine, feces, menses, andother discharges. Typically, in the case of adults, the articles takethe form of sanitary napkins, adult incontinence pads, and adultincontinence diapers or undergarments. One of the primary drivers of thedesirability of these products to wearers is to give them assurance thatwhen they experience incontinence, the occurrence of such will gounnoticed by others and even more ideally by the wearers.

One way of improving the performance and overall discretion ofdisposable absorbent articles that has been widely utilized bymanufacturers has been the inclusion of superabsorbent polymers whichare able to intake increased amounts of liquid and consequently form aswollen hydrogel material. The resulting hydrogel serves to retain fluidsuch as discharged body liquids within the structure. An absorbentstructure of this type wherein hydrogel-forming materials in particulateform are incorporated into fibrous webs is disclosed in Weisman andGoldman; U.S. Pat. No. 4,610,678; issued Sep. 9, 1986.

While disposable absorbent articles with these superabsorbent materialstend to be highly absorbent and less bulky, there are a number of usersof these products that have a relatively high body mass index (BMI)(i.e., about 25 or greater) for which these products still leave much tobe desired. In particular, these users tend to experience exaggeratedbunching of the absorbent article during wear and as a result there canbe increased opportunity for leaks to occur.

Consequently, there is a need for a disposable absorbent article whichtargets to provide increased protection from leakage to consumers whichhave a relatively high BMI while maintaining a level of discretion tothe wearer while in use. There is also a need for designers of such anarticle to take into account the perceived absorbency needs of theseconsumers as well even when the overall volume to be absorbed isrelatively light to moderate.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter which is regarded as formingthe present invention, it is believed that the invention will be betterunderstood from the following description which is taken in conjunctionwith the accompanying drawings in which the designations are used todesignate substantially identical elements and in which:

FIG. 1 is a plan view showing an exemplary embodiment of a disposableabsorbent article of the present invention, which is an incontinencepad.

FIG. 2 is a cross-sectional view of the incontinence pad shown in FIG. 1taken along 2-2.

FIG. 3 is a plan view of the pad of FIG. 1 with the primary topsheetremoved.

FIG. 4 is a cross-sectional view of the absorbent core of the pad ofFIG. 3.

FIG. 5 is a cross-sectional view of an alternate absorbent core of thepad of FIG. 3 taken along 2-2.

FIG. 6 is a perspective view of a SABAP apparatus useful for the SABAPmethod described herein.

FIG. 7 is a side view of a deposition assembly and bottom view of topplate assembly of the SABAP apparatus of FIG. 6.

FIG. 8 is side view of an apparatus or tensile tester for use in a BunchCompression Method of the present invention.

FIG. 9a is a side view of the tensile tester of FIG. 8 upon initialplacement of a specimen.

FIG. 9b is a side view of the tensile tester of FIG. 9 once the specimenhas been compressed.

FIG. 10a is an exemplary graph of bunch compression curves where forceversus displacement of samples tested is shown pursuant to a BunchCompression Method as detailed herein

FIG. 10b is a bunch compression curve of an exemplary graph of an areaunder the curve useful for calculating an Energy of Compression pursuantto a Bunch Compression Method detailed herein.

DETAILED DESCRIPTION

The disposable absorbent articles, particularly incontinence pads orpants, of the present invention can provide flexibility to allow for animproved and comfortable fit which is less susceptible to bunchingduring use. In particular, it is envisioned that the articles of thepresent invention exhibit heightened structural resiliency from theproposed configuration and orientation of the layers contained therein.For the purposes of this disclosure, reference to an incontinence pad,disposable absorbent article, or absorbent article will be used.However, the present invention may be applied to a plurality ofabsorbent articles including, but not limited to, sanitary napkins,pantiliners, menstrual pads, diapers, training pants, adult incontinencepants, etc.

There are several factors to consider when designing a disposableabsorbent article like an incontinence pad, particularly if improved fitand performance are desired. First, the stiffness of the pad is animportant factor. Typically, thinner pads offer less stiffness thantheir bulkier counterparts. While bulkier pads may be less likely tosuccumb to the compression that is typical during wear, bulkier pads areless desirable because they can cause the incontinence pad to lose itsdiscreetness during use. Furthermore, some flexibility in the absorbentcore can allow the incontinence pad to adjust more readily to thecontours of the body of a user during use. Second, the absorbency of thepad is key in determining whether or not the pad is useful forconsumers. Ideally, the pad is well suited to accommodate either smallor large loads of exudates. This accommodation means not only storingeither type of load sufficiently but also effectively and quicklywicking such loads from a body-contacting surface of the pad such thatthe user experiences little to no feeling of wetness after the releaseof the load. In the case of a small load, a wearer should be able tocontinue to wear the pad for some reasonable time after a release sinceimmediate changing of the pad may not be feasible or desired.

In the past, incontinence pad designs have required a bit of compromiserelative to these factors. In contrast, the absorbent articles, whichinclude but are not limited to incontinence, designed pursuant to thepresent invention account for these factors to arrive at an absorbentarticle which exhibits improved protection against leakage, particularlyfor those wearers of a higher than average body mass index (BMI).Namely, incontinence pads of the present invention provide good coreflexibility, excellent wicking, distribution, and overall absorbency,and in certain embodiments, may include barrier cuffs which stand upduring use and contact the wearer in an appropriate location areincluded as part of the construction to further protect against alikelihood of leakage from the pad.

FIG. 1 shows an absorbent article of the present invention or moreparticularly an incontinence pad or sanitary napkin 10 (referred tomainly as “incontinence pad” herein) may comprise a longitudinal axis 80and a lateral axis 90. The longitudinal axis 80 generally extendsparallel to the longest dimension of the incontinence pad 10. Thelateral axis 90 extends generally perpendicular to the longitudinal axis80 and lies in the same plane as the incontinence pad 10 in a flattenedstate on a flat surface. The lateral axis 90 bisects the length of theincontinence pad 10 where the length is parallel to the longitudinalaxis 80, and the longitudinal axis 80 bisects the width of theincontinence pad 10 where the width is parallel to the lateral axis 90.Additionally, as shown, the MD direction may be generally parallel tothe longitudinal axis 80 of the incontinence pad 10, and the CDdirection may be generally parallel to the lateral axis 90.

The incontinence pad 10 comprises a generally elongated oval shape.However, any suitable shape may be utilized. Some examples includehourglass (peanut), offset hourglass (one end is wider than an oppositeend and a narrowed mid-section between the ends), etc. The incontinencepad 10 may be symmetric about the longitudinal axis 80 or asymmetricabout the longitudinal axis 80. Similarly, the incontinence pad 10 maybe symmetric about the lateral axis 90 or asymmetric about the lateralaxis 90.

The incontinence pad 10 may further comprise a chassis 20 comprising aplurality of side edges 22 and 24 which extend generally parallel to thelongitudinal axis 80. A pair of end edges 26 and 28 join each of theside edges 22 and 24. One end edge 26 joins the side edges 22 and 24 inthe first end region 40 of the incontinence pad 10 while the other endedge 28 joins the side edges 22 and 24 in the second end region 48 ofthe incontinence pad 10—the second end region 48 being opposite thefirst end region 40. An intermediate region 44 is disposed between thefirst end region 40 and the second end region 48.

The chassis 20 of FIG. 1 is shown in cross-section in FIG. 2. Amongother things, the chassis 20 comprises a primary topsheet 203. Thisprimary topsheet has a body-facing surface 203A and a garment-facingsurface 203B. This chassis 20 of the pad 10 further comprises abacksheet 207 which also comprises its own body-facing surface 207A andopposing garment-facing surface 207B. These two components sandwich anabsorbent core 205. In other words, the absorbent core 205 is disposedbetween the topsheet 203 and the backsheet 207. All three components(i.e., topsheet 203, backsheet 207, and absorbent core 205) form thechassis 20 of the pad 10. Additional layers may very well be includedwithin this chassis 20, particularly between the topsheet 203 and thebacksheet 207 but it should be noted that these layers are separate andapart from the absorbent core. Suitable additional layers may includesecondary topsheets, acquisition layers, additional distribution layersover and above those which will be discussed below, and other usefullayers. In the case of a secondary topsheet, it is disposed beneath theprimary topsheet 203 and on the body-facing surface of the core. Incertain embodiments, the secondary topsheet (also known as the “STS”)has a greater length and width than the absorbent core 205.

The chassis 20 further comprises a wearer-facing surface 20A and agarment-facing surface 20B. The wearer-facing surface 20A may comprisethe topsheet 203, and the garment-facing surface 20B may comprise thebacksheet.

The absorbent core 205 is formed from multiple layers and is directed toquickly acquiring the bodily fluid or exudates and distributing themalong a length of the core. FIG. 3 depicts the absorbent core of thepresent invention as it shows a plan view of the pad 10 with the primarytopsheet 203 removed for viewing of the absorbent core 205 positionedabove the backsheet 207. FIG. 4 shows a cross-section of this absorbentcore 205 in more detail. The absorbent core 205 comprises a firstlaminate 60 which includes a first superabsorbent layer 61 disposed on afirst distribution layer 62. The first laminate 60 has an upper surface60A and a lower surface 60B which opposes the upper surface.Additionally, the first laminate 60 has a first end 66 and a second end67 which opposes the first end 66. The absorbent core 205 furtherincludes a second laminate 70 which includes a second superabsorbentlayer 71 disposed on a second distribution layer 72. This secondlaminate 70 also has an upper surface 70A and a lower surface 70B, afirst end 76, and a similar opposing second end 77. In the embodiment ofFIGS. 3 and 4, the first distribution layer 62 is joined to the seconddistribution layer 72 in an offset manner or configuration along thelength of the core. As used herein “offset” or “offset manner” meansthat the layers or laminates of interest are staggered and that theirrespective first ends or second ends are not aligned in the z-direction(i.e., the first end of one layer or laminate is not coterminous withthe second end of an adjacent underlying or overlying layer or laminate)when the layers or laminates overlay one another. This offset joinder ofthe first and second distribution layers 62, 72 results in anoverlapping and joined area of the two laminates that forms a centralportion 205C of the absorbent core 205. The central portion 205C of thecore is consequently bounded on each side by a front end portion and arear end portion 205R, both of the core. In other words, the front endportion 205F and the rear end 205R portion are respectively disposed atopposing ends of the core 205. The front end portion 205F is formed froma first end 66 or second end 67 of the first laminate 60 while the rearend portion 205F of the core 205 is formed by the first end 76 or secondend 77 of the second laminate 70. In the embodiment of FIG. 3, the firstends 66, 76 of the first and second laminates oppose each other and forma front end portion 205F and a rear end portion 205R of the absorbentcore 205, respectively. In an alternate embodiment, the second ends 67,77 of the first and second laminates may oppose each other and form afront end portion 205F and a rear end portion 205R of the absorbent core205, respectively. In both instances, the first ends 66, 76 are in theform of a male connection derived from a nested cut of the first andsecond laminates. Similarly, the second ends 67, 77 are in the form of afemale connection derived from a nested cut of the first and secondlaminates, respectively.

In an alternate embodiment, the first laminate 60 and the secondlaminate 70 may be joined to superabsorbent layer 71 instead of thesecond distribution layer. In this instance, the laminates are joined toone another in an offset manner as well except the first distributionlayer 62 is joined to the second superabsorbent layer 71 instead of thesecond distribution layer.

In one embodiment, the overlapping area or region that forms the centralportion 205C of the core 205 has at least one characteristic of agreater capacity, a greater void volume, or a greater thickness than thefront end portion 205F and the rear end portion 205F of the absorbentcore 205. This embodiment is particularly useful for providing forheightened leakage protection in the central portion where female usersof such pads would typically contact the pad and release fluids.

Applicant shall now provide more detailed insight into thecharacteristics of the article that have been found to be desirable toprovide consumers with the discretion and leak-proof benefits they seek.

Article Length

Over and above the elemental portions described herein, the overallarticle exhibits an article length of from about 371 mm to about 500 mmaccording to the Article Length Method. In certain embodiments, thearticle length is greater than 371 mm, 380 mm, 390 mm, and 395 mm andless than 500 mm, 490 mm, 480 mm, 470 mm, 460 mm, 450 mm, 440 mm, 430mm, 420 mm, and 410 mm. In an embodiment, the article length is about400 mm. he length of the disposable absorbent article is important for avariety of reasons. First, the article must be of sufficient length tocover the intended area of insult that the article is likely toexperience during use. This means that to the extent a consumer expectsthat the fluids dispelled during the time of article wear are relativelyminimal due since the product is being worn during the day time andthere is easier access to toilet facilities, a shorter pad may suffice.Additionally, a shorter pad may also be more suitable during the daywhen the wearer's body is in a seated or standing position and the areaof insult is almost orthogonal to the area of fluid expulsion, i.e., thegenitalia. As a wearer's absorbency needs increase for reasons such asinaccessibility to toilet facilities, heightened inability to controlurine events due to decreased mobility or weakened bladder control, itis likely desirable to increase the pad length to allow forincorporation of more absorbent material and a greater area of coveragewhere expelled fluids may be retained. Additionally, a disposableabsorbent article that is worn at night or while a wearer is in a bedtends to be of the longest pad length. This is typically the case forsince the wearer may not be able to react as quickly as required toreach the toilet facilities in a timely fashion if sleeping or layingdown. Moreover, as a wearer is laying down and fluids are expelled,there is usually a tendency of the expelled fluids to creep fartheralong the length of the pad due to the gravitational pull on the fluidalong the surface of the genital area to the gluteal area if she islaying on their back or to the groin if she is laying on their stomach.It should be noted that although article length may typically be assumedto correspond to a pad type product, it is envisioned herein that such apad could very well be integrated into a pant product that may be wornin place of underwear.

Acquisition Time

Another important property of the disposable absorbent articles of thepresent invention is the speed with which they absorb expelled fluids.In order to meet the needs of the relatively high BMI consumer, it iskey that she feel that her absorbency requirements are being met whenshe dons an incontinence product or a similar product. In reality, it islikely that many commercially available incontinence products arecapable of absorbing the fluids to which they are exposed. The consumer,however, wants confidence that the product will absorb fluids quicklyand do so with minimal bulk. The articles of the present invention takethis concern into account. As such, pursuant to the Speed of Acquisitionwith Balloon Applied Pressure Method, the present articles exhibit anAcquisition Time for a load of 60 ml of less than about 39 seconds, lessthan about 37 seconds, less than about 35 seconds, or even less thanabout 30 seconds. This test method focuses on characterizing the abilityof a product to absorb rather substantial gushes of fluid. The articleof the present invention is focused on providing a balance of acceptablerate of fluid acquisition along with an acceptable product thickness (oreven thinness) and further an ability to recover when exposed tocompressive forces.

Dry Pad Thickness

In conjunction with the abovementioned properties, the articles of thepresent invention also exhibit a dry pad thickness of between about 5 mmto about 11 mm according to a Pad Thickness Method. As mentionedrelative to the desirable acquisition time, it is important to theconsumer that she be able to wear her disposable absorbent product withconfidence in its absorbency performance. Almost as critical asabsorbency to her is the concept of the article being discreet. Thismeans that the consumer would like to wear the article without it beingnoticeable by others and without a constant reminder to herself that sheis wearing it because she needs to wear it. From this perspective, it isdesirable that the article be as thin as feasible. Therefore, thearticles of the present invention exhibit a dry pad thickness of greaterthan about 5 mm, 5.5 mm, or 6 mm and less than about 11 mm, 10 mm, 9 mm,8.5 mm, 8 mm, 7.5 mm, or 7 mm.

Energy of Recovery

From a physical property point of view, the articles of the presentinvention also exhibit a particular Energy of Recovery at a load of 30ml of from about 4 mJ to about 11 mJ according to a Bunch CompressionMethod. In certain embodiments where the pad length is greater thanabout 330 mm, the Energy of Recovery is measured on a dry pad and thearticles of the present invention exhibit an Energy of Recovery whiledry of greater than 4.4 mJ. One of the primary concerns of wearers ofincontinence is the perceived lack of protection that results when awearer's incontinence product bunches in the crotch area during wear.This is particularly prevalent in situations where the wearer has arelatively high BMI since the product may likely be subject to heightedbunching due to the pressure of the convergence of the wearer's thighs.In order to address this concern, the present invention is focused ondelivering a disposable article that not only addresses the requirementsfor absorbency and discretion but equally addresses the need to resistbunching as a result of compression. The resistance to bunching duringwear is even more critical once the article has been insulted by fluidwhich is typically when articles sag and deform away from the body ofthe wearer due to the weight of the fluid. This resistance to bunchingtends to only increase in criticality as the number of insults or gushesof fluids occur in the same article or product. Thus, it is desirable,as has been envisioned in the case of the present invention that thearticle exhibit sufficient resistance to bunching to accommodatemultiple fluid gushes and maintain sufficient closeness to or contactwith the genital area where fluid is exiting the body. This ensures thatthe likelihood of leaks are minimized and ultimately leads to heightenedconfidence of the article wearer. This resistance to bunching ischaracterized as an energy of recovery and is measured in conjunctionwith an insult of 30 ml of fluid as detailed in the Bunch CompressionMethod. In certain embodiments, the Energy of Recovery at a load of 30ml according to this Bunch Compression Method is greater than about 4ml, 4.3 ml, 4.5 ml, 5.1 mJ or 5.2 mJ and less than about 11 mJ, 10 mJ, 9mJ, 8 mJ, 7 mJ, or 6 mJ.

The individual components of these disposable absorbent articles thatare envisioned to enable and deliver these properties are detailedbelow.

Primary Topsheet

The primary topsheet 203 (also referred to herein “topsheet”) of thechassis 20 is positioned adjacent a body-facing surface 203A of theabsorbent core 205 and may be joined thereto and to the backsheet 207 byattachment methods (not shown) such as those well known in the art.Suitable attachment methods are described with respect to joining thebacksheet 207 to the absorbent core 205. The topsheet 203 and thebacksheet 207 may be joined directly to each other in the incontinencepad periphery and may be indirectly joined together by directly joiningthem to the absorbent core 205 or additional optional layers within thechassis like a secondary topsheet which spans the entire or partial areaof the article. This indirect or direct joining may be accomplished byattachment methods which are well known in the art.

The absorbent article may comprise any known or otherwise effectiveprimary topsheet, such as one which is compliant, soft feeling, andnon-irritating to the wearer's skin. Suitable primary topsheet materialsinclude a liquid pervious material that is oriented towards and contactsthe body of the wearer permitting bodily discharges to rapidly penetratethrough it without allowing fluid to flow back through the topsheet tothe skin of the wearer. The primary topsheet, while being capable ofallowing rapid transfer of fluid through it, also provides for thetransfer or migration of the lotion composition onto an external orinternal portion of a wearer's skin. A suitable topsheet can be made ofvarious materials such as woven and nonwoven materials; apertured filmmaterials including apertured formed thermoplastic films, aperturedplastic films, and fiber-entangled apertured films; hydro-formedthermoplastic films; porous foams; reticulated foams; reticulatedthermoplastic films; thermoplastic scrims; or combinations thereof.

Apertured film materials suitable for use as the topsheet include thoseapertured plastic films that are non-absorbent and pervious to bodyexudates and provide for minimal or no flow back of fluids through thetopsheet. Nonlimiting examples of other suitable formed films, includingapertured and non-apertured formed films, are more fully described inU.S. Pat. No. 3,929,135, issued to Thompson on Dec. 30, 1975; U.S. Pat.No. 4,324,246, issued to Mullane et al. on Apr. 13, 1982; U.S. Pat. No.4,342,314, issued to Radel et al. on Aug. 3, 1982; U.S. Pat. No.4,463,045, issued to Ahr et al. on Jul. 31, 1984; U.S. Pat. No.5,006,394, issued to Baird on Apr. 9, 1991; U.S. Pat. No. 4,609,518,issued to Curro et al. on Sep. 2, 1986; and U.S. Pat. No. 4,629,643,issued to Curro et al. on Dec. 16, 1986. Commercially available formedfilmed topsheets include those topsheet materials marketed by theProcter & Gamble Company (Cincinnati, Ohio) under the DRI-WEAVE®tradename.

Nonlimiting examples of woven and nonwoven materials suitable for use asthe topsheet include fibrous materials made from natural fibers,modified natural fibers, synthetic fibers, or combinations thereof.These fibrous materials can be either hydrophilic or hydrophobic, but itis preferable that the topsheet be hydrophobic or rendered hydrophobic.As an option, portions of the topsheet can be rendered hydrophilic, bythe use of any known method for making topsheets containing hydrophiliccomponents. One such method include treating an apertured film componentof a nonwoven/apertured thermoplastic formed film topsheet with asurfactant as described in U.S. Pat. No. 4,950,264, issued to Osborn onAug. 21, 1990. Other suitable methods describing a process for treatingthe topsheet with a surfactant are disclosed in U.S. Pat. Nos. 4,988,344and 4,988,345, both issued to Reising et al. on Jan. 29, 1991. Thetopsheet may have hydrophilic fibers, hydrophobic fibers, orcombinations thereof.

A particularly suitable topsheet comprises staple length polypropylenefibers having a denier of about 1.5, such as Hercules type 151polypropylene marketed by Hercules, Inc. of Wilmington, Del. As usedherein, the term “staple length fibers” refers to those fibers having alength of at least about 15.9 mm (0.62 inches).

When the primary topsheet comprises a nonwoven fibrous material in theform of a nonwoven web, the nonwoven web may be produced by any knownprocedure for making nonwoven webs, nonlimiting examples of whichinclude spunbonding, carding, wet-laid, air-laid, meltblown,needle-punching, mechanical entangling, thermo-mechanical entangling,and hydroentangling. A specific example of a suitable meltblown processis disclosed in U.S. Pat. No. 3,978,185, to Buntin et al., issued Aug.31, 1976. The nonwoven may be compression resistant as described in U.S.Pat. No. 7,785,690 entitled “Compression Resistant Nonwovens” issued onAug. 31, 2010. The nonwoven web may have loops as described in U.S. Pat.No. 7,838,099 entitled “Looped Nonwoven Web” issued on Nov. 23, 2010.

Other suitable nonwoven materials include low basis weight nonwovens,that is, nonwovens having a basis weight of from about 18 g/m² to about25 g/m². An example of such a nonwoven material is commerciallyavailable under the tradename P-8 from Veratec, Incorporation, adivision of the International Paper Company located in Walpole, Mass.Other nonwovens are described in U.S. Pat. Nos. 5,792,404 and 5,665,452.

The topsheet may comprise tufts as described in U.S. Pat. No. 8,728,049entitled “Absorbent Article Having a Tufted Topsheet” issued on May 20,2014, U.S. Pat. No. 7,553,532 entitled “Tufted Fibrous Web” issued onJun. 30, 2009, U.S. Pat. No. 7,172,801 entitled “Tufted Laminate Web”issued on Feb. 6, 2007, or U.S. Pat. No. 8,440,286 entitled “CappedTufted Laminate Web” issued on May 14, 2013. The primary topsheet mayhave an inverse textured web as described in U.S. Pat. No. 7,648,752entitled “Inverse Textured Web” issued on Jan. 19, 2010. Tufts are alsodescribed in U.S. Pat. No. 7,410,683 entitled “Tufted Laminate Web”issued on Aug. 12, 2008.

The primary topsheet may have a pattern of discrete hair-like fibrils asdescribed in U.S. Pat. No. 7,655,176 entitled “Method of Making aPolymeric Web Exhibiting A Soft and Silky Tactile Impression” issued onFeb. 2, 2010 or U.S. Pat. No. 7,402,723 entitled “Polymeric WebExhibiting A Soft And Silky Tactile Impression” issued on Jul. 22, 2008.

The primary topsheet may comprise one or more structurally modifiedzones as described in U.S. Pat. No. 8,614,365 entitled “AbsorbentArticle” issued on Dec. 24, 2013. The primary topsheet may have one ormore out of plane deformations as described in U.S. Pat. No. 8,704,036entitled “Sanitary Napkin for Clean Body Benefit” issued on Apr. 22,2014. The primary topsheet may have a masking composition as describedin U.S. Pat. No. 6,025,535 entitled “Topsheet For Absorbent ArticlesExhibiting Improved Masking Properties” issued on Feb. 15, 2000.

Another suitable primary topsheet or a primary topsheet combined with asecondary topsheet may be formed from a three-dimensional substrate asdetailed in a U.S. provisional patent application No. 62/306,676 filedon Mar. 11, 2016 in the name of Jill M. Orr and entitled “AThree-Dimensional Substrate Comprising a Tissue Layer”. Thisthree-dimensional substrate has a first surface, a second surface, landareas and also comprises three-dimensional protrusions extending outwardfrom the second surface of the three-dimensional substrate, wherein thethree-dimensional protrusions are surrounded by the land areas. Thesubstrate is a laminate comprising at least two layers in a face to facerelationship, the second layer is a tissue layer facing outward from thesecond surface of the three-dimensional substrate, and the tissue layercomprises at least 80% pulp fibers by weight of the tissue layer.

The primary topsheet may have comprises one or more layers, for examplea spunbond-meltblown-spunbond material. The primary topsheet may beapertured, may have any suitable three-dimensional features, and/or mayhave a plurality of embossments (e.g., a bond pattern). The topsheet maybe apertured by overbonding a material and then rupturing the overbondsthrough ring rolling, such as disclosed in U.S. Pat. No. 5,628,097, toBenson et al., issued on May 13, 1997. Additional lateral extensibilityin the chassis 20 (i.e., in the primary topsheet and/or the backsheet)may be provided in a variety of ways. For example, either the primarytopsheet or backsheet may be pleated by any of many known methods.Alternatively, all or a portion of the chassis (i.e., also the primarytopsheet and/or backsheet) may be made of a formed web material or aformed laminate of web materials like those described in U.S. Pat. No.5,518,801 issued on 21 May 1996 in the name of Chappell et al. Such aformed web material includes distinct laterally extending regions inwhich the original material has been altered by embossing or anothermethod of deformation to create a pattern of generally longitudinallyoriented alternating ridges and valleys. The formed web material alsoincludes laterally extending unaltered regions located between thelaterally extending altered regions.

Secondary Top sheet

As noted previously, the disposable absorbent articles of the presentdisclosure may comprise additional layers, one of which includes asecondary topsheet. As mentioned previously, the secondary topsheet maybe separate and apart from the absorbent core. Additionally, thesecondary topsheet is disposed beneath the primary topsheet 203 and onthe body-facing surface of the core. In some forms, the secondarytopsheet may have a basis weight from about 40 gsm to about 100 gsm,from about 45 gsm to about 75 gsm, or from about 50 gsm to about 60 gsm,specifically including all values within these ranges and any rangescreated thereby. In some forms, the secondary topsheet may comprise ahomogeneous mix of fibers.

In other forms, the secondary topsheet may comprise a heterogeneous mixof fibers. For example, typically a plurality of carding machines feed aspunlace process. The types of fibers supplied to the cards may behomogeneously blended as mentioned above. Or in contrast, the types offibers or the weight percentage of the fibers provided to the cardingmachines may be different. In such forms, where the types of fibersand/or the weight percentage of the fibers are varied to the cardingmachines, the resulting spunlaced structure may comprise a plurality ofheterogeneous strata which are—after the spunlacing process—integralwith one another.

For those forms where a secondary topsheet comprises a plurality ofheterogeneous strata, an acquisition gradient may be achieved withcareful selection of the fibers within each of the stratum of thesecondary topsheet. For example, a first stratum—being closest inproximity to the primary topsheet—may comprise a lower amount ofabsorbent fiber as opposed to a stratum which is disposed further fromthe primary topsheet. In such forms, the first stratum may comprise frombetween about 20 weight percent to about 30 weight percent of absorbentfiber while an opposing stratum disposed furthest from the primarytopsheet may comprise about 35 percent by weight of absorbent fiber. Insuch forms, the weight percentage of the stiffening fiber may stayconstant among the strata or may be varied to create a stiffnessgradient in the secondary topsheet in addition to the absorbencygradient. Similarly, in some forms, the resilient fibers may stayconstant among the strata or may be varied to create a permeabilitygradient in the secondary topsheet in addition to the absorbencygradient or in addition to the stiffness gradient. Forms arecontemplated where the secondary topsheets of the present disclosurecomprise between 2 to 4 strata.

Some exemplary fibers that may be included in the secondary topsheet mayinclude absorbent fibers, stiffening fibers, and resilient fibers. Formsare contemplated where at least one of the absorbent fibers, stiffeningfibers, and/or resilient fibers comprise a hydrophilic coating. Suitablehydrophilic coatings are known in the art. Additionally, in some forms,the one or more of the above fibers of the secondary topsheet maycomprise a staple length, e.g. about 38 mm.

Any suitable absorbent fibers may be utilized. Conventional absorbentfibers include cotton, \ rayon or regenerated cellulose. In somespecific forms, the secondary topsheet may comprise viscose cellulosefibers. Due to the proximity of the secondary topsheet to the topsheet,the absorbent fibers can help to pull liquid insults from the topsheetinto the absorbent core disposed beneath the secondary topsheet. In someforms, the secondary topsheet may comprise from about 20 percent toabout 50 percent by weight, from about 21 percent to about 40 percent byweight, from about 25 percent to about 30 percent by weight,specifically including any values within these ranges and any rangescreated thereby. In one specific form, the secondary topsheet maycomprise about 25 percent by weight absorbent fibers.

It is worth noting that a higher weight percentage of absorbent fibersmay be beneficial for fluid insults that are more viscous, e.g.menstrual fluid. However, the introduction of a higher weight percentageof absorbent fibers can negatively impact resiliency and stiffness ofthe secondary topsheet. And, too low of a weight percentage of absorbentfibers can result in a more ‘wet feeling’ topsheet which can create anegative impression of the product in consumers' minds. The weightpercentages provided above may work well in the context of urinary fluidinsults.

Any suitable size of absorbent fiber may be utilized. A suitable measureof size can be linked to linear density. In some forms, the absorbentfiber linear density may range from about 2 dtex to about 4 dtex, about2.5 dtex to about 3.7 dtex, or from about 2.8 dtex to about 3.5 dtex,specifically reciting all values within these ranges and any rangescreated thereby. In one specific form, the absorbent fiber may comprisea dtex of about 3.3.

The absorbent fibers may have any suitable shape. In some forms, atrilobal shape may be utilized. The trilobal shape can improve wickingand improve masking. Trilobal rayon is available from Kelheim Fibres andsold under the trade name Galaxy.

In addition to absorbent fibers, as mentioned previously, the secondarytopsheet may also comprise stiffening fibers. Stiffening fibers may beutilized to help provide structural integrity to the secondary topsheetweb material. The stiffening fibers can help increase structuralintegrity of the secondary topsheet in a machine direction and in across machine direction which facilitate web manipulation duringprocessing of the secondary topsheet for incorporation into a disposableabsorbent article. For example, the secondary topsheets of the presentdisclosure may be heat stiffened. The heat stiffening process can createa plurality of connection points amongst the stiffening fibers. Ingeneral, the higher the number of connection points, the stiffer thesecondary topsheet. So, while the creation of a plurality of connectionpoints is beneficial for processability, the creation of too manyconnection points can lead to a secondary topsheet which isuncomfortable in its respective disposable absorbent article. With thatin mind, the constituent material of the stiffening fibers, the weightpercentage of the stiffening fibers, and heat of processing should becarefully selected. The heat stiffening process is discussed hereafter.

With the foregoing in mind, any suitable stiffening fiber may beutilized. Some examples of suitable stiffening fibers includebi-component fibers comprising polyethylene and polyethyleneterephthalate components or polyethylene terephthalate andco-polyethylene terephthalate components. The components of thebi-component fiber may be arranged in a core sheath arrangement, a sideby side arrangement, an eccentric core sheath arrangement, a trilobalarrangement, or the like. In one specific example, the stiffening fibersmay comprise bi-component fibers having polyethylene/polyethyleneterephthalate components arranged in a concentric, core—sheatharrangement where the polyethylene is the sheath. In some forms,monocomponent fibers may be utilized. In such forms, the constituentmaterial of the monocomponent may comprise polypropylene.

Any suitable size of stiffening fiber may be utilized. Suitable lineardensities of stiffening fiber may be from about 4 dtex to about 12 dtex,from about 4.5 dtex to about 10 dtex, or from about 5 dtex to about 7dtex, specifically reciting all values within these ranges and anyranges created thereby. In one specific form, the stiffening fibers maycomprise 5.8 dtex polyethylene/polyethylene terephthalate bi-componentfibers arranged in a core and concentric sheath arrangement.

Any suitable weight percentage of stiffening fibers may be utilized inthe secondary topsheeet as well. However, in some forms, the secondarytopsheet of the present disclosure may be heat treated (heat stiffened).The heat treatment can create connection points amongst the fibers ofthe secondary topsheet. So, where there is a higher percentage ofstiffening fibers, more connection points may be created. The additionalconnection point can yield a much stiffer secondary topsheet which maynegatively impact comfort. In some forms, the secondary topsheet maycomprise about 20 percent to about 40 percent by weight stiffeningfibers or from about 25 percent to about 35 percent by weight stiffeningfibers, specifically including all values within these ranges and anyranges created thereby.

As noted previously, the secondary topsheet of the present disclosuremay additionally comprise resilient fibers. The resilient fibers canhelp the secondary topsheet maintain its permeability. Any suitable sizefiber may be utilized. In some forms, the resilient fibers can have alinear density of about 6 dtex to about 12 dtex, from about 8 dtex toabout 11 dtex, or from about 9 dtex to about 10 dtex, specificallyreciting all values within these ranges and any ranges created thereby.In one specific form, the resilient fibers may be comprise a lineardensity of about 10 dtex. In one specific example, the resilient fibersmay comprise 10 dtex hollow spiral polyethylene terephthalate fibers.

It is worth noting, that if smaller fiber sizes are utilized, theresiliency of the secondary topsheet would be expected to decrease. And,with the decreased size at the same weight percentage, a higher numberof fibers per gram would equate to a decrease in permeability of thesecondary topsheet. Additionally, some conventional secondary topsheetmay utilize superabsorbent polymer, e.g. AGM, to help drain theirrespective topsheets. As noted previously, AGM typically swells whenabsorbing fluid insults and can reduce permeability of secondarytopsheets by occluding openings in the secondary topsheet. However, ingeneral, conventional secondary topsheets have lower permeability whichhelps reduce the likelihood that the AGM will occlude openings of theseconventional secondary topsheets upon swelling. In contrast, due to thehigher permeability of the secondary topsheets of the presentdisclosure, AGM may not be suitable for utilization therewith withoutadditional measures ensuring that the AGM will not greatly reduce thepermeability thereof. Rather, AGM may be provided in a separate layer inan absorbent article.

Any suitable weight percentage of resilient fibers may be utilized. Insome forms, the secondary topsheet of the present disclosure maycomprise from about 25 percent to about 55 percent by weight resilientfibers, between 35 percent and 50 percent resilient fibers, or between40 percent and 45 percent by weight resilient fibers, specificallyincluding any values within these ranges and any ranges created thereby.In some specific forms, the secondary topsheet may comprise about 45percent by weight resilient fibers. In some specific forms, thesecondary topsheet may comprise about 45 percent, 10 dtex, hollow spiralpolyethylene terephthalate fibers.

With regard to the heat stiffening process, any suitable temperature maybe utilized. And, the suitable temperature may be impacted, in part, bythe constituent chemistry of the stiffening fibers as well as byprocessing speed of the secondary topsheet web. In some forms, thesecondary topsheet web may be heat stiffened at a temperature of 132degrees Celsius. It is also worth noting that in order to provide auniform stiffness property across the secondary topsheet web, anyheating operation should be set up to provide uniform heating to thesecondary topsheet web. Even small variations in temperature can greatlyimpact the tensile strength of the secondary topsheet web. For example,for two comparable secondary topsheets having a basis weight of about 50gsm, both with the above formulations, a significant difference wascreated with a small temperature difference. A heat stiffening processat 135 degrees C. yielded a CD direction tensile strength for one samplethat was twice the CD direction tensile strength of a sample subjectedto a 132 degrees C. stiffening process. A similar result was witnessedfor samples having comparable compositions and about a 70 gsm basisweight. Additionally, there was about a 1.5 times difference for the MDdirection tensile strength where the sample subjected to the highertemperature, i.e. 135 degrees C., had a higher tensile strength in theMD direction.

Data is provided below in Table 1 regarding a comparison between acommercially available secondary topsheet and a secondary topsheet ofthe present disclosure.

TABLE 1 Comparative Experimental STS STS Sample Sample Basis Weight(gsm) 75 50. Thickness (mm) — 1.05 Thickness Slitted (mm) 1. 0.80 FluidAcquisition (s) 1.2 1.2 Rewet (g) 3.5 2 Wicking MD (mm) 25 20 Airpermeability 250 400 (m³/m²/min) Tensile strength MD (N) 25 20 Tensilestrength CD (N) 6 6 Modulus MD (N/cm) 50 50 Opacity (%) — 43

The experimental sample from Table 1 was a 50 gsm basis weight secondarytopsheet comprising 25% galaxy 3.3 dtex trilobal rayon available fromKelheim Fibres; 30% 5.8 detex PE/PET bicomponent,concentric—core/sheath—PE sheath; 45%, 10 dtex, 38 mm staple length,hollow spiral polyethylene terephthalate fibers.

Backsheet

The backsheet 207 of the chassis 20 may be positioned adjacent agarment-facing surface of the absorbent core 205 and may be joinedthereto by attachment methods (not shown) such as those well known inthe art. For example, the backsheet 207 may be secured to the absorbentcore 205 by a uniform continuous layer of adhesive, a patterned layer ofadhesive, or an array of separate lines, spirals, or spots of adhesive.Alternatively, the attachment methods may comprise using heat bonds,pressure bonds, ultrasonic bonds, dynamic mechanical bonds, or any othersuitable attachment methods or combinations of these attachment methodsas are known in the art. Forms of the present disclosure are alsocontemplated wherein the absorbent core 205 is not joined to thebacksheet 207, the topsheet 203, or both.

The backsheet 207 may be impervious, or substantially impervious, toliquids (e.g., urine) and may be manufactured from a thin plastic film,although other flexible liquid impervious materials may also be used. Asused herein, the term “flexible” refers to materials which are compliantand will readily conform to the general shape and contours of the humanbody. The backsheet 207 may prevent, or at least inhibit, the exudatesabsorbed and contained in the absorbent core 205 from wetting articlesof clothing which contact the incontinence pad 10 such as undergarments.However, in some instances, the backsheet 207 may permit vapors toescape from the absorbent core 205 (i.e., is breathable) while in otherinstances the backsheet 207 may not permit vapors to escape (i.e.,non-breathable). Thus, the backsheet 205 may comprise a polymeric filmsuch as thermoplastic films of polyethylene or polypropylene. A suitablematerial for the backsheet 207 is a thermoplastic film having athickness of from about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils),for example. Any suitable backsheet known in the art may be utilizedwith the present invention.

The backsheet 207 acts as a barrier to any absorbed bodily fluids thatmay pass through the absorbent core 205 to the garment surface thereofwith a resulting reduction in risk of staining undergarments or otherclothing. Further, the barrier properties of the backsheet permit manualremoval, if a wearer so desires, of the interlabial absorbent articlewith reduced risk of hand soiling. A preferred material is a soft,smooth, compliant, liquid and vapor pervious material that provides forsoftness and conformability for comfort, and is low noise producing sothat movement does not cause unwanted sound.

The backsheet may comprise a wet laid fibrous assembly having atemporary wet strength resin incorporated therein as described in U.S.Pat. No. 5,885,265 (Osborn, III.) issued Mar. 23, 1999. The backsheetmay further be coated with a water resistant resinous material thatcauses the backsheet to become impervious to bodily fluids withoutimpairing the spreading of adhesive materials thereon.

Another suitable backsheet material is a polyethylene film having athickness of from about 0.012 mm (0.5 mil) to about 0.051 mm (2.0 mils).The backsheet may be embossed and/or matte finished to provide a morecloth-like appearance. Further, the backsheet may permit vapors toescape from the absorbent core 42 (i.e., the backsheet is breathable)while still preventing body fluids from passing through the backsheet. Apreferred microporous polyethylene film which is available from TredegarCorporation, Virginia, USA, under Code No. XBF-1 12W.

For a stretchable but non-elastic backsheet, one material can be used isa hydrophobic, stretchable, spun laced, non-woven material having abasis weight of from about 30 to 40 g/m2, formed of polyethyleneterephthalate or polypropylene fibers. This material is breathable, i.e.permeable to water vapor and other gases.

For an elastic backsheet, one material which can be used is an elasticfilm sold under the trade mark EXX500 by Exxon Corporation. The materialof this film is formed from an elastomeric base composition consistingof a styrene block copolymer. However, this material is not breathable.Another material which can be used for an elastic backsheet is a plasticfilm that has been subjected to a process that provides it withelastic-like properties without attaching elastic strands to the film,and may for example comprise a formed film made in accordance with U.S.Pat. No. 4,342,314 (Radel et al) and U.S. Pat. No. 4,463,045 (Ahr etal).

Suitable breathable backsheets for use herein include all breathablebacksheets known in the art. In principle there are two types ofbreathable backsheets, single layer breathable backsheets which arebreathable and impervious to liquids and backsheets having at least twolayers, which in combination provide both breathability and liquidimperviousness. Suitable single layer breathable backsheets for useherein include those described for example in GB A 2184 389, GB A 2184390, GB A 2184 391, U.S. Pat. No. 4,591,523, U.S. Pat. No. 3 989 867,U.S. Pat. No. 3,156,242 and WO 97/24097.

The backsheet may have two layers: a first layer comprising a gaspermeable aperture formed film layer and a second layer comprising abreathable microporous film layer as described in U.S. Pat. No.6,462,251 (Cimini) issued Oct. 8, 2002. Suitable dual or multi-layerbreathable backsheets for use herein include those exemplified in U.S.Pat. Nos. 3,881,489, 4,341,216, 4,713,068, 4,818,600, EP 203 821, EP 710471, EP 710 472, and EP 793 952.

The backsheet may be a relatively hydrophobic 18 grams per square meter(gsm) spunbonded nonwoven web of 2 denier polypropylene fibers. Thebacksheet may also be a laminate as is known in the art.

The backsheet may be vapor permeable as described in U.S. Pat. No.6,623,464 (Bewick-Sonntag) issued Sep. 23, 2003 or U.S. Pat. No.6,664,439 (Arndt) issued Dec. 16, 2003. The backsheet can be formed fromany vapor permeable material known in the art. Backsheet can be amicroporous film, an apertured formed film, or other polymer film thatis vapor permeable, or rendered to be vapor permeable, as is known inthe art.

The backsheet may be a nonwoven web having a basis weight between about20 gsm and about 50 gsm. In one embodiment, the backsheet is arelatively hydrophobic 23 gsm spunbonded nonwoven web of 4 denierpolypropylene fibers available from Fiberweb Neuberger, under thedesignation F102301001. The backsheet may be coated with a non-soluble,liquid swellable material as described in U.S. Pat. No. 6,436,508(Ciammaichella) issued Aug. 20, 2002. The backsheet has a garment-facingside and an opposite body-facing side. The garment-facing side of thebacksheet comprises a non-adhesive area and an adhesive area. Theadhesive area may be provided by any conventional means. Pressuresensitive adhesives have been commonly found to work well for thispurpose.

Absorbent Core

The absorbent core 205 of the present invention may comprise anysuitable shape including but not limited to an oval, a discorectangle, arectangle, an asymmetric shape, and an hourglass. For example, in someforms of the present invention, the absorbent core 205 may comprise acontoured shape, e.g. narrower in the intermediate region than in theend regions. As yet another example, the absorbent core may comprise atapered shape having a wider portion in one end region of the pad whichtapers to a narrower end region in the other end region of the pad. Theabsorbent core 205 may comprise varying stiffness in the MD and CD.

As detailed earlier, the absorbent core 205 comprises a first laminateand a second laminate. Both are generally compressible, conformable,non-irritating to the wearer's skin, and capable of absorbing andretaining liquids such as urine and other certain body exudatesincluding menses.

The configuration and construction of the absorbent core 205 may vary(e.g., the absorbent core 205 may have varying caliper zones, ahydrophilic gradient, a superabsorbent gradient, or lower averagedensity and lower average basis weight acquisition zones). Further, thesize and absorbent capacity of the absorbent core 205 may also be variedto accommodate a variety of wearers. However, the total absorbentcapacity of the absorbent core 205 should be compatible with the designloading and the intended use of the disposable absorbent article orincontinence pad 10.

In some forms of the present invention, the absorbent core 205 maycomprise a plurality of multi-functional layers that are in addition tothe first and second laminates. For example, the absorbent core 205 maycomprise a core wrap (not shown) useful for enveloping the first andsecond laminates and other optional layers. The core wrap may be formedby two nonwoven materials, substrates, laminates, films, or othermaterials. In a form, the core wrap may only comprise a single material,substrate, laminate, or other material wrapped at least partially arounditself.

The absorbent core 205 of the present disclosure may comprise one ormore adhesives, for example, to help immobilize the SAP or otherabsorbent materials within the first and second laminates.

Absorbent cores comprising relatively high amounts of SAP with variouscore designs are disclosed in U.S. Pat. No. 5,599,335 to Goldman et al.,EP 1,447,066 to Busam et al., WO 95/11652 to Tanzer et al., U.S. Pat.Publ. No. 2008/0312622A1 to Hundorf et al., and WO 2012/052172 to VanMalderen. These may be used to configure the superabsorbent layers.

Additions to the core of the present disclosure are envisioned. Inparticular, potential additions to the current multi-laminate absorbentcore are described in U.S. Pat. No. 4,610,678, entitled “High-DensityAbsorbent Structures” issued to Weisman et al., on Sep. 9, 1986; U.S.Pat. No. 4,673,402, entitled “Absorbent Articles With Dual-LayeredCores”, issued to Weisman et al., on Jun. 16, 1987; U.S. Pat. No.4,888,231, entitled “Absorbent Core Having A Dusting Layer”, issued toAngstadt on Dec. 19, 1989; and U.S. Pat. No. 4,834,735, entitled “HighDensity Absorbent Members Having Lower Density and Lower Basis WeightAcquisition Zones”, issued to Alemany et al., on May 30, 1989. Theabsorbent core may further comprise additional layers that mimic thedual core system containing an acquisition/distribution core ofchemically stiffened fibers positioned over an absorbent storage core asdetailed in U.S. Pat. No. 5,234,423, entitled “Absorbent Article WithElastic Waist Feature and Enhanced Absorbency” issued to Alemany et al.,on Aug. 10, 1993; and in U.S. Pat. No. 5,147,345. These are useful tothe extent they do not negate or conflict with the effects of the belowdescribed laminates of the absorbent core of the present invention.

Laminates

The first and second laminates 60, 70 of the absorbent core 205 havebeen detailed earlier but it is important to note that these laminatesmay have cross-direction widths that are the same as each other ordifferent. For instance, the first laminate may have a lessercross-direction width than said second laminate or a greatercross-direction width than said second laminate. In certain instances,the first and second laminates have machine-direction lengths that arethe same while in other instances, the first and second laminates havemachine-direction lengths that are different. In the latter instance,the first laminate may have a lesser machine-direction length than thesecond laminate or conversely the first laminate may have a greatermachine-direction length than said second laminate.

The first and second laminates 60, 70 may further comprise an optionalintermediate layer disposed between the respective superabsorbent layerand distribution layer. This optional intermediate layer may comprisematerials detailed herein relative to the optional layers for thechassis, in general.

Additionally, although the invention requires a first and secondlaminate, the absorbent article or incontinence pad of the presentinvention may further comprise an optional laminate comprising asuperabsorbent layer and a distribution layer. This optional laminatemay take the form of a third, fourth, fifth, or even additionallaminates. The superabsorbent layer and distribution layer may exhibitthe same or different properties detailed earlier with respect to thefirst and second superabsorbent and distribution layers. This optionallaminates may be disposed on a body-facing surface of the first laminateor second laminate or on a garment-facing surface of the first laminateor second laminate.

The first and second laminates each have a first end 66, 76 that iscomplementary in shape to its respective second end 67, 77. Morespecifically, the first end 66 of the first laminate conforms shapewiseto the second end 67 of the same laminate. The same conformance appliesto the first end 76 of the second laminate relative to the second end 77of the second laminate. For instance, the first end 66 of the firstlaminate fits into the second end 67 of the first laminate. Thisconformation results from a nested cut in the laminate that providesmatching or shape fitting ends. This is also the case for the secondlaminate's respective first 76 and second ends 77. Likewise, thisfeature may also be prevalent in any optional laminates that might beincorporated into the absorbent core. This nesting or nested cut featureof the laminate allows for reduced waste of trim during manufacture. Ithas also been found that it is possible to configure the first andsecond laminates in a manner that allows for their respective first endsto oppose one another when the first and second distribution layers areoverlapped and joined forming an absorbent core with a central portion205C comprising an overlapping area. A front end portion of the core205F is formed from a first end 66, 76 of either the first laminate orthe second laminate. A rear end portion of the core 205R is similarlyformed from a first end 66, 76 of the other of the first laminate or thesecond laminate. This configuration yields an absorbent core withmatching (i.e., a male connection) ends. The first end of each laminatehas a male connection while the second end of each laminate has a femaleconnection. In such instances, the male connection of the first end fitsinto (conforms to the shape of) the female connection of the second endof the same laminate. In another embodiment, a front end portion of thecore is formed from a first end 66, 76 of either the first laminate orthe second laminate while the rear end portion of the core is formedfrom a second end 67, 77 of the other of the first laminate or secondlaminate. In this instance, the second end is shaped as a femaleconnection and therefore does not match the front end portion of thesame core. In a third embodiment, the front end portion of the core isformed from a second end of either the first laminate or the secondlaminate. A rear end portion of the core is similarly formed from asecond end of the remaining first laminate or the second laminate. Thisconfiguration yields an absorbent core with matching (i.e., a femaleconnection) ends. It should be noted, however, that the width of thefirst and second laminates may be the same or different as mentionedherein. The nested cuts of the first and second ends of each of thefirst and second laminates have shapes selected from the groupconsisting of arcs, semicircles, semi-ellipses, chevrons, rectangles,sinusoids, jigsaws, and combinations thereof.

In one embodiment, in addition to the topsheet and backsheet, the coremay comprise the first laminate having a first end which iscomplementary in shape to its respective second end and wherein saidlaminate includes a first superabsorbent layer disposed onto a firstdistribution layer and a second laminate having a first end which iscomplementary in shape to its respective second end and wherein saidlaminate includes a second distribution layer joined to a secondsuperabsorbent layer; wherein said first laminate layer is joined tosaid second laminate layer in an offset manner along a length of theabsorbent article wherein the absorbent core has a front end portionthat is formed by the first end of the second laminate.

In terms of the method of manufacture of the laminates of the presentinvention, it has been found that it is preferred to form the firstlaminate and the second laminate from a single laminate that is slitalong its machine-direction length. This method is useful only when thefirst and second superabsorbent layers are the same and the first andsecond distribution layers are the same. This sameness may be withregard to one or more of shape, basis weight, and material. The samenessof material for the distribution layer is preferred. Once the singlelaminate is slit to form the first and second laminates, these first andsecond laminates are joined. In a certain embodiment, the first andsecond laminates are joined at their respective distribution layers tothe other in an offset manner as detailed herein and may be done so viastandard mechanical, thermal, or chemical methods known to those skilledin the art.

In certain embodiments, the first or second laminates may include one ormore recessed areas that run along the machine direction or crossdirection. These recessed areas may coincide with the discontinuouspatterns of one or more of a superabsorbent layer and distributionlayer, whether it be of the first laminate, second laminate, or both.These recessed areas may also merely be formed by embossing of the firstor second laminates. These recessed areas may alternatively be formed byslitting, cutting, ring-rolling, or otherwise providing mechanicaldeformation through the first and/or second laminates. Each manner ofrecessed area formation mentioned herein is intended to yield a recessedarea that is capable of providing a point of preferential bending of theoverall article. For instance, FIG. 5 shows an alternativecross-sectional view of an alternate core 205′ at 2-2 where recessedareas 88 are either gaps or embossed channels in the first and secondlaminates 60′, 70′ of absorbent core 205′, in the machine direction.These recessed areas 88 need not be present in both first and secondlaminates 60′, 70′ along the entirety of each of their lengths. Therecessed areas 88 may be present in the machine direction only in theoverlapping joinder area of the first and second laminates, 60′ 70′.Alternatively, the recessed areas 88 may be present in the in the crossdirection along the length of the first and second laminates, 60′, 70′or only in the overlapping joinder of the two laminates. In instanceslike these, the laminates through which the recessed areas are effectedwill be prone to bending more easily. In instances where a recessed area88 is present in only one of a first and second laminate, it is expectedthat there will be a preferential tendency for the pad 20 to bend at therecessed area 88. This means if the first laminate is closer to the bodythan the second laminate, the pad will likely bend away from the body.The opposite may be true as well in the event the second laminate 70′placed away from the body comprises a recessed area and the firstlaminate 60′ does not. In this instance, the pad 20 may exhibitpreferential tendency to bend toward the body. Depending on the overallconfiguration of the pad, either type of bending may be preferred in aparticular instance.

Superabsorbent Layers

The first and second superabsorbent layers 61, 71 of the first andsecond laminates 60, 70 comprise superabsorbent polymers or absorbentgelling materials (AGM). The superabsorbent layers may comprise AGMparticles or AGM fibers. In general, such AGM's have been used only fortheir fluid-absorbing properties. Such materials form hydrogels oncontact with fluid (e.g., with urine, blood, and the like). One highlypreferred type of hydrogel-forming, absorbent gelling material is basedon the hydrolyzed polyacids, especially neutralized polyacrylic acid.Hydrogel-forming polymeric materials of this type are those which, uponcontact with fluids (i.e., liquids) such as water or body fluids, imbibesuch fluids and thereby form hydrogels. In this manner, fluid dischargedinto the fluid absorbent structures herein can be acquired and held.These preferred superabsorbent polymers will generally comprisesubstantially water-insoluble, slightly cross-linked, partiallyneutralized, hydrogel-forming polymer materials prepared frompolymerizable, unsaturated, acid-containing monomers. In such materials,the polymeric component formed from unsaturated, acid-containingmonomers may comprise the entire gelling agent or may be grafted ontoother types of polymer moieties such as starch or cellulose. Thehydrolyzed polyacrylic acid grafted starch materials are of this lattertype. Thus the preferred superabsorbent polymers include hydrolyzedpolyacrylonitrile grafted starch, hydrolyzed polyacrylate graftedstarch, polyacrylates, maleic anhydride-iso-butylene copolymers andcombinations thereof. Especially preferred superabsorbent polymers arethe hydrolyzed polyacrylates and hydrolyzed polyacrylate grafted starch.

Whatever the nature of the polymer components of the preferredsuperabsorbent polymers, such materials will in general be slightlycross-linked. Cross-linking serves to render these preferredhydrogel-forming absorbent materials substantially water-insoluble, andcross-linking also in part determines the gel volume and extractablepolymer characteristics of the hydrogels formed therefrom. Suitablecross-linking agents are well known in the art and include, for example:(1) compounds having at least two polymerizable double bonds; (2)compounds having at least one polymerizable double bond and at least onefunctional group reactive with the acid-containing monomer material; (3)compounds having at least two functional groups reactive with theacid-containing monomer material; and (4) polyvalent metal compoundswhich can form ionic cross-linkages. Preferred cross-linking agents arethe di- or polyesters of unsaturated mono- or polycarboxylic acids withpolyols, the bisacrylamides and the di- or triallyl amines. Especiallypreferred cross-linking agents are N,N′-methylenebisacrylamide,trimethylol propane triacrylate and triallyl amine. The cross-linkingagent will generally comprise from about 0.001 mole percent to about 5mole percent of the preferred materials. More preferably, thecross-linking agent will comprise from about 0.01 mole percent to about3 mole percent of the absorbent gelling materials used herein.

The preferred, slightly cross-linked, hydrogel-forming absorbent gellingmaterials will generally be employed in their partially neutralizedform. For purposes described herein, such materials are consideredpartially neutralized when at least about 25 mole percent, 50 molepercent, or even 75 mole percent, of monomers used to form the polymerare acid group-containing monomers which have been neutralized with asalt-forming cation. Suitable salt-forming cations include alkali metal,ammonium, substituted ammonium and amines. This percentage of the totalmonomers utilized which are neutralized acid group-containing monomersis referred to as the “degree of neutralization.” Typically, commercialsuperabsorbent polymers have a degree of neutralization somewhat lessthan about 90%.

The preferred superabsorbent polymers used herein are those which have arelatively high capacity for imbibing fluids encountered in the fluidabsorbent articles; this capacity can be quantified by referencing the“gel volume” of said superabsorbent polymers. Gel volume can be definedin terms of the amount of synthetic urine absorbed by any given fluidabsorbent gelling agent buffer and is specified as grams of syntheticurine per gram of gelling agent.

Gel volume in synthetic urine can be determined by forming a suspensionof about 0.1-0.2 parts of dried fluid absorbent gelling material to betested with about 20 parts of synthetic urine. This suspension ismaintained at ambient temperature under gentle stirring for about 1 hourso that swelling equilibrium is attained. The gel volume (grams ofsynthetic urine per gram of fluid absorbent gelling material) is thencalculated from the weight fraction of the gelling agent in thesuspension and the ratio of the liquid volume excluded from the formedhydrogel to the total volume of the suspension. The preferredsuperabsorbent polymers useful in this invention will have a gel volumeof from about 20 to 70 grams, more preferably from about 30 to 60 grams,of synthetic urine per gram of absorbent gelling material.

The superabsorbent polymers hereinbefore described are typically used inthe form of discrete particles. Such superabsorbent polymers can be ofany desired shape, e.g., spherical or semi-spherical, cubic, rod-likepolyhedral, etc. Shapes having a large greatest dimension/smallestdimension ratio, like needles and flakes, are also contemplated for useherein. Agglomerates of fluid absorbent gelling material particles mayalso be used.

The size of the fluid absorbent gelling material particles may vary overa wide range. For reasons of industrial hygiene, average particle sizessmaller than about 30 microns are less desirable. Particles having asmallest dimension larger than about 2 mm may also cause a feeling ofgrittiness in the absorbent article, which is undesirable from aconsumer aesthetics standpoint. Furthermore, rate of fluid absorptioncan be affected by particle size. Larger particles have very muchreduced rates of absorption. Fluid absorbent gelling material particlespreferably have a particle size of from about 30 microns to about 2 mmfor substantially all of the particles. “Particle Size” as used hereinmeans the weighted average of the smallest dimension of the individualparticles.

These layers are preferably substantially free of airfelt and are thusdistinct from mixed layers that may include airfelt. As used herein,“substantially free of airfelt” means less than 5%, 3%, 1%, or even 0.5%of airfelt. In a preferred case, there will be no measurable airfelt inthe superabsorbent layers. In the case of the first superabsorbentlayer, it is preferably disposed onto the first distribution layerdiscontinuously. As used herein “discontinuously” or “in a discontinuouspattern” means that the superabsorbent polymers are applied onto thefirst distribution layer in a pattern of disconnected shaped areas.These areas of superabsorbent polymers or areas free of superabsorbentpolymer may include, but are not limited to linear strips, non-linearstrips, circles, rectangles, triangles, waves, mesh, and combinationsthereof. The first superabsorbent layer like the second superabsorbentlayer may, however, be disposed onto its respective distribution layerin a continuous pattern. As used herein “continuous pattern” or“continuously” means that the material is deposited and or secured to asuperabsorbent carrier material and/or the adjacent distribution layerin an uninterrupted manner such that there is rather full coverage ofthe distribution layer by the superabsorbent polymer.

In certain embodiments, the first and second superabsorbent layers maycomprise superabsorbent polymers that are the same. In otherembodiments, the first and second superabsorbent layers may comprisesuperabsorbent polymers that are different from one another. This is maybe in addition to the different deposition patterns that are discussedabove.

The superabsorbent layers are disposed having a thickness of 0.2 mm, 0.3mm, 0.4 mm, or 0.5 mm to 1 mm, 1.2 mm, 1.4 mm, 1.8 mm, or 2 mm. Thefirst and second superabsorbent layers may have the same or differentcross-direction widths as applied to their respective distributionlayers. For instance, the cross-direction widths of the first and secondsuperabsorbent layers may be from 20 mm, 25 mm, 30 mm, 35 mm, or 40 mmto 50 mm, 60 mm, 65 mm, 70 mm, 80 mm, or 90 mm. Alternatively, inembodiments where the widths of the first and second superabsorbentlayers differ from one another in the cross-direction width, the firstsuperabsorbent layer may have a lesser cross-direction width than thesecond superabsorbent layer. In particular, the first superabsorbentlayer may have a cross-direction width that is less than about 95%, 90%,80%, 70%, or even 60% of the width of the second superabsorbent layer.

In certain embodiments, the one or both of the first and secondsuperabsorbent layers span greater than greater than about 50%, 60%,70%, 80%, 90%, or even 95% of the cross-direction width of asuperabsorbent carrier layer and/or the respective adjoining first orsecond distribution layer.

Like the optional layers that may be included in the chassis, theabsorbent core may also comprise similar optional layers. They may bewebs selected from the group consisting of a fibrous structure, anairlaid web, a wet laid web, a high loft nonwoven, a needlepunched web,a hydroentangled web, a fiber tow, a woven web, a knitted web, a flockedweb, a spunbond web, a layered spunbond/melt blown web, a carded fiberweb, a coform web of cellulose fiber and melt blown fibers, a coform webof staple fibers and melt blown fibers, and layered webs that arelayered combinations thereof.

These optional layers of the core and of the chassis may comprisematerials such as creped cellulose wadding, fluffed cellulose fibers,airfelt, and textile fibers. The materials of the optional layers mayalso be fibers such as, for example, synthetic fibers, thermoplasticparticulates or fibers, tricomponent fibers, and bicomponent fibers suchas, for example, sheath/core fibers having the following polymercombinations: polyethylene/polypropylene, polyethylvinylacetate/polypropylene, polyethylene/polyester, polypropylene/polyester,copolyester/polyester, and the like. The optional layers may be anycombination of the materials listed above and/or a plurality of thematerials listed above, alone or in combination.

The materials of the optional layers may be hydrophobic or hydrophilicdepending on their placement within the chassis.

The materials of the optional layers may comprise constituent fiberscomprising polymers such as polyethylene, polypropylene, polyester, andblends thereof. The fibers may be spunbound fibers. The fibers may bemeltblown fibers. The fibers may comprise cellulose, rayon, cotton, orother natural materials or blends of polymer and natural materials. Thefibers may also comprise a superabsorbent material such as polyacrylateor any combination of suitable materials. The fibers may bemonocomponent, bicomponent, and/or biconstituent, non-round (e.g.,capillary channel fibers), and may have major cross-sectional dimensions(e.g., diameter for round fibers) ranging from 0.1-500 microns. Theconstituent fibers of the nonwoven precursor web may also be a mixtureof different fiber types, differing in such features as chemistry (e.g.polyethylene and polypropylene), components (mono- and bi-), denier(micro denier and >20 denier), shape (i.e., capillary and round) and thelike. The constituent fibers may range from about 0.1 denier to about100 denier.

The optional layers may include thermoplastic particulates or fibers.The materials, and in particular thermoplastic fibers, may be made froma variety of thermoplastic polymers including polyolefins such aspolyethylene (e.g., PULPEX™) and polypropylene, polyesters,copolyesters, and copolymers of any of the foregoing.

Depending upon the desired characteristics, suitable thermoplasticmaterials include hydrophobic fibers that have been made hydrophilic,such as surfactant-treated or silica-treated thermoplastic fibersderived from, for example, polyolefins such as polyethylene orpolypropylene, polyacrylics, polyamides, polystyrenes, and the like. Thesurface of the hydrophobic thermoplastic fiber may be renderedhydrophilic by treatment with a surfactant, such as a nonionic oranionic surfactant, e.g., by spraying the fiber with a surfactant, bydipping the fiber into a surfactant or by including the surfactant aspart of the polymer melt in producing the thermoplastic fiber. Uponmelting and resolidification, the surfactant will tend to remain at thesurfaces of the thermoplastic fiber. Suitable surfactants includenonionic surfactants such as Brij 76 manufactured by ICI Americas, Inc.of Wilmington, Del., and various surfactants sold under the Pegosperse™by Glyco Chemical, Inc. of Greenwich, Conn. Besides nonionicsurfactants, anionic surfactants may also be used. These surfactants maybe applied to the thermoplastic fibers at levels of, for example, fromabout 0.2 to about 1 g/cm² of thermoplastic fiber.

Suitable thermoplastic fibers may be made from a single polymer(monocomponent fibers), or may be made from more than one polymer (e.g.,bicomponent fibers). The polymer comprising the sheath often melts at adifferent, typically lower, temperature than the polymer comprising thecore. As a result, these bicomponent fibers provide thermal bonding dueto melting of the sheath polymer, while retaining the desirable strengthcharacteristics of the core polymer.

Suitable bicomponent fibers for use in the present invention may includesheath/core fibers having the following polymer combinations:polyethylene/polypropylene, polyethylvinyl acetate/polypropylene,polyethylene/polyester, polypropylene/polyester, copolyester/polyester,and the like. Particularly suitable bicomponent thermoplastic fibers foruse herein are those having a polypropylene or polyester core, and alower melting copolyester, polyethylvinyl acetate or polyethylene sheath(e.g., DANAKLON™, CELBOND™, or CHISSO™ bicomponent fibers). Thesebicomponent fibers may be concentric or eccentric. As used herein, theterms “concentric” and “eccentric” refer to whether the sheath has athickness that is even, or uneven, through the cross-sectional area ofthe bicomponent fiber. Eccentric bicomponent fibers may be desirable inproviding more compressive strength at lower fiber thicknesses. Suitablebicomponent fibers for use herein may be either uncrimped (i.e., unbent)or crimped (i.e., bent). Bicomponent fibers may be crimped by typicaltextile means such as, for example, a stuffer box method or the gearcrimp method to achieve a predominantly two-dimensional or “flat” crimp.

The length of bicomponent fibers may vary depending upon the particularproperties desired for the fibers and the web formation process.Typically, in an airlaid web, these thermoplastic fibers have a lengthfrom about 2 mm to about 12 mm long such as, for example, from about 2.5mm to about 7.5 mm long, and from about 3.0 mm to about 6.0 mm long.Nonwoven fibers may be between 5 mm long and 75 mm long, such as, forexample, 10 mm long, 15 mm long, 20 mm long, 25 mm long, 30 mm long, 35mm long, 40 mm long, 45 mm long, 50 mm long, 55 mm long, 60 mm long, 65mm long, or 70 mm long. The properties-of these thermoplastic fibers mayalso be adjusted by varying the diameter (caliper) of the fibers. Thediameter of these thermoplastic fibers is typically defined in terms ofeither denier (grams per 9000 meters) or decitex (grams per 10,000meters). Suitable bicomponent thermoplastic fibers as used in an airlaidmaking machine may have a decitex in the range from about 1.0 to about20 such as, for example, from about 1.4 to about 10, and from about 1.7to about 7 decitex.

The compressive modulus of these thermoplastic materials, and especiallythat of the thermoplastic fibers, may also be important. The compressivemodulus of thermoplastic fibers is affected not only by their length anddiameter, but also by the composition and properties of the polymer orpolymers from which they are made, the shape and configuration of thefibers (e.g., concentric or eccentric, crimped or uncrimped), and likefactors. Differences in the compressive modulus of these thermoplasticfibers may be used to alter the properties, and especially the densitycharacteristics, of the respective thermally bonded fibrous matrix.

The optional layers may also include synthetic fibers that typically donot function as binder fibers but alter the mechanical properties of thefibrous webs. Synthetic fibers include cellulose acetate, polyvinylfluoride, polyvinylidene chloride, acrylics (such as Orlon), polyvinylacetate, non-soluble polyvinyl alcohol, polyethylene, polypropylene,polyamides (such as nylon), polyesters, bicomponent fibers, tricomponentfibers, mixtures thereof and the like. These might include, for example,polyester fibers such as polyethylene terephthalate (e.g., DACRON™, andKODEL™), high melting crimped polyester fibers (e.g., KODEL™ 431 made byEastman Chemical Co.) hydrophilic nylon (HYDROFIL™), and the like.Suitable fibers may also hydrophilized hydrophobic fibers, such assurfactant-treated or silica-treated thermoplastic fibers derived from,for example, polyolefins such as polyethylene or polypropylene,polyacrylics, polyamides, polystyrenes, polyurethanes and the like. Inthe case of nonbonding thermoplastic fibers, their length may varydepending upon the particular properties desired for these fibers.Typically they have a length from about 0.3 to 7.5 cm, such as, forexample from about 0.9 to about 1.5 cm. Suitable nonbondingthermoplastic fibers may have a decitex in the range of about 1.5 toabout 35 decitex, such as, for example, from about 14 to about 20decitex.

Distribution Layers

The first and second distribution layers are useful for wicking bodilyfluids away from the skin of a wearer to facilitate comfort of continuedwear after a release. In an embodiment, the first and seconddistribution layers of the first and second laminates not only face oneanother but are joined in an offset manner to form part of the core. Thedistribution layers comprise one or more of cellulose and commuted woodpulp. This may be in the form of airlaid. The airlaid may be chemicallyor thermally bonded. In particular, the airlaid may be multi bondedairlaid (MBAL). In this instance, the distribution layer may furthercomprise a fibrous thermoplastic adhesive material at least partiallybonding the airlaid to itself and adjacent distribution layers,superabsorbent layers, or other additional (optional) layers. It shouldbe noted that the same materials that are suitable for the optionallayers of the chassis are envisioned as suitable for use in thedistribution layers. The basis weight for each of the first and seconddistribution layers range from 80 gsm, 80 gsm, 100 gsm, 110 gsm, 120gsm, or 130 gsm to 140 gsm, 150 gsm, 160 gsm, 180 gsm, 200 gsm, 220 gsm,or 240 gsm. A preferred basis weight is 135 gsm for each of thedistribution layers of the first and second laminates.

Barrier Cuffs

The incontinence pad 10 may further comprise a first barrier cuff 230Aand a second barrier cuff 230B and fastening adhesive 211 disposed onthe garment-facing surface 20B of the chassis 20. As shown, thefastening adhesive 211 may not extend out laterally to the same extentas the absorbent core 205. As such, constructions where pad curl isreduced would be beneficial.

The first barrier cuff 230A and the second barrier cuff 230B may beattached to the chassis 20 in any suitable location. For example, asshown, the first barrier cuff 230A and the second barrier cuff 230B maybe attached to a wearer-facing surface 20A of the chassis 20. As shown,the first barrier cuff 230A and the second barrier cuff 230B areattached to the primary topsheet 203. In some forms, the first barriercuff 230A and the second barrier cuff 230B may be attached to agarment-facing surface 20B of the chassis 20. For example, the firstbarrier cuff 230A and the second barrier cuff 230B may be attached tothe backsheet 207. Some examples of other suitable barrier cuffs aredescribed in U.S. Pat. Nos. 4,695,278; 4,704,115; 4,795,454; 4,909,803;U.S. Patent Application Publication No. 2009/0312730.

As shown, in some forms, the first barrier cuff 230A comprises a firstcover 231 and a first elastic member 233. The second barrier cuff 230Bcomprises a second cover 235 and a second elastic member 237. As shown,the first cover 231 may fully enclose the first elastic member 233.Similarly, the second cover 235 may fully enclose the second elasticmember 237.

While the first barrier cuff 230A and the second barrier cuff 230B areshown as discrete elements which are attached to the chassis 20, anysuitable configuration may be utilized. For example, the first cover 231and/or the second cover 235 may comprise a portion of the primarytopsheet 203 and/or a portion of the backsheet 207. In such forms, thefirst barrier cuff 230A and/or the second barrier cuff 230B may beintegrally formed with the chassis 20. A form where the first barriercuff 230A and the second barrier cuff 230B are integrally formed withthe chassis 20 is shown in FIG. 2 and discussed hereafter.

Referring to FIG. 2, the first elastic member 233 and the second elasticmember 237 may be attached to the first cover 231 and the second cover235, respectively, by any suitable means. In one example, the firstelastic member may be adhesively attached to the first cover 231.Similarly, the second elastic member 237 may be adhesively attached tothe second cover 235. For example, as shown, first adhesive portions 251and 253 may attach the elastic members 233 and 237 to their respectivecovers 231 and 235. Similarly, second adhesive portions 255 and 257 mayattach their respective covers 231 and 235 to the primary topsheet 203.As described below, the first elastic member 233 and the second elasticmember 237 may be attached in only a portion the first cover 231 andsecond cover 235, respectively. Additional forms are contemplated wherethe first elastic member 233 and/or the second elastic member 237 areattached to the chassis 20 in conjunction with or independently fromtheir respective covers 231 and 235.

Referring to FIG. 2, the elastic members 233 and 237 may be disposedlaterally inboard of side edges 205A and 205B of the absorbent core 205.In other forms, the elastic members 233 and 237 may be disposedlaterally outboard of the side edges 205A and 205B of the absorbent core205. Still in other forms, the elastic members 233 and 237 may bedisposed laterally inboard of the side edges 205A and 205B of theabsorbent core 205 in the first end region 40 and the second end region48 but laterally outboard of side edges 205A and 205B of the absorbentcore 205 in the intermediate region 44. Additional forms arecontemplated where the elastic members 233 and 237 are disposedlaterally inboard of the side edges 205A and 205B of the absorbent core205 in the first end region 40 but are disposed outboard of the sideedges 205A and 205B of the absorbent core 205 in the intermediate region44 and/or the second end region 48.

The elastic members comprised by the barrier cuffs can be glued in, invarious glue lengths using various glues and glue amounts andplacements. Placement of the glue is yet another variable which shouldbe considered especially when designed with the core flexibility inmind. Gluing of the elastic members and the covers create anchor pointson the pad.

The covers of the barrier cuffs of the present invention can be made ofvarying types of nonwovens of different MD and CD flexibility. The covercan be bonded to the topsheet of the absorbent article, such as, forexample, by a slot coated stripe of adhesive, glue beads, ultrasonicsealing, or other suitable bonding agents. In certain forms of thepresent invention, the cover can be bonded to the backsheet at the sideedges 22 and 24 (see FIG. 1) of the pad, such as, for example, using acrimp or other suitable bonding agents, such as, for example, adhesive.

Elastic members may comprise any suitable elastic material. Somesuitable examples include Spandex™ or other similar polyurethanes,natural or synthetic rubber, styrene block copolymers, metallocenepolyolefins, Lycra™, or any other suitable elastomer materials known inthe art. Preferably the elastic member is durable for ease of processingand for during the use of the article and exhibits excellent elasticity(recovery after strain) even under strains as high as 400%.

Additionally, the elastic members of the present disclosure may compriseany suitable dtex. In other forms, the elastic members may comprise adtex of 680 or less. In some forms, the elastic members may have a dtexbetween 680 and 470, specifically including all numbers within the rangeand any ranges created thereby.

Minimum spacing between the first barrier cuff 230A and the secondbarrier cuff 230B may be largely driven by female anatomy. However,tradeoffs can occur where the barrier cuffs (and their respectiveelastic members) are disposed too far outboard of the absorbent core 205and too far inboard of the absorbent core 205. As such, spacing betweenthe most distal elastic members of their respective barrier cuffs shouldbe carefully selected. Starting from the narrowest width, spacingbetween the most distal elastic members of the first barrier cuff 230Aand the second barrier cuff 230B should be large enough to allowsufficient access to the absorbent core 205 during use while also takinginto account the forces which will be applied to the pad. If too narrow,access to a portion of the absorbent core 205 could be obstructed whichcould lead to leakage despite the barrier cuffs 230A and 230B. In someforms of the present invention, minimum spacing between the elasticmember of the first barrier cuff 230A and the elastic member of thesecond barrier cuff 230B which are most distal to one another may be atleast 20 mm. Any suitable spacing may be utilized. For example, in someforms of the present invention, the spacing may be greater than or equalto about 20 mm, greater than about 30 mm, greater than about 33 mm,greater than about 35 mm, greater than about 40 mm, greater than about45 mm, greater than about 50 mm, greater than about 54 mm, greater thanabout 60 mm, greater than about 65 mm, less than or equal to about 70mm, or less than about 65 mm, or less than about 60 mm, less than about55 mm, less than about 50 mm, less than about 45 mm, less than about 40mm, less than about 35 mm, less than about 30 mm, less than about 25 mm,specifically including any values within these ranges or any rangescreated thereby.

Fold Lines

Yet another factor that contributes to fit is the folds or fold lines ofthe pad. Pads generally contain one or more folds in order to make thepad more consumer friendly and easy to transport and store.Additionally, folding the pad can reduce the likelihood of elastic creepduring storage. However, these fold lines can act as bending points uponwhich elastomeric forces can act to deform the shape of the pad. And,similar to the anchor points discussed above, anchor points disposed toofar beyond a fold line can be problematic. Anchor points disposed toofar beyond a fold line can increase the torque lever arm acting on thepad in the MD direction causing pad curl and/or the pad to fold backinto the folded state.

Referring back to FIG. 1, incontinence pad 10 may further comprise afirst fold line 50 and a second fold line 55. The first fold line 50 candefine a boundary between the first end region 40 and the intermediateregion 44. The second fold line 55 can define a boundary between thesecond end region 48 and the intermediate region 44. The first endregion 40 can be defined by the end edge 26, the first fold line 50, anda portion of the side edges 22 and 24 disposed between the end edge 26and the first fold line 50. The intermediate area 44 can be by the firstfold line 50, the second fold line 55, and a portion of the side edges22 and 24 disposed between the first fold line 50 and second fold line55. The second end region 48 is defined by the second fold line 55, endedge 28, and a portion of the side edges 22 and 24 disposed between theend edge 28 and the second fold line 55. The fold lines 50 and 55 can beparallel and can be co-linear (on average) with the folds which arecreated via the packaging process for the incontinence pad 10.

In some forms, the first fold line 50 and second fold line 55, may beconfigured such that the fold lines 50 and 55 dissect the pad intothirds. In other forms, the first fold line 50 may be offset toward theend edge 28, and the second fold line 55 may be offset toward the endedge 28. In such forms, this can allow the second end region 48 to betucked between the intermediate region 44 and the first end region 40when the pad is in the folded configuration.

Additional Features

In some forms of the present invention, the incontinence pads orsanitary napkins may comprise wings. Wings can provide additionalleakage protection for the incontinence pad and can help secure the padto the underwear of the user. Any suitable wing configuration known inthe art may be utilized.

All the components can be adhered together with adhesives, including hotmelt adhesives, as is known in the art. The adhesive can be FindlayH2128 UN or Savare PM 17 and can be applied using a Dynafiber HTWsystem.

Per FIG. 2, during use, the pad can be held in place by any support orattachment suitable for such purposes. In certain forms of the presentinvention, the pad is placed in the user's undergarment or panty andsecured thereto by the fastening adhesive 211. The fastening adhesive211 secures the pad in the crotch portion of the user's panty. A portionor all of the garment-facing surface 20B of the chassis 20 is coatedwith fastening adhesive 211. Any adhesive or glue suitable for suchpurposes can be used for the fastening adhesive 211 herein, such as, forexample, using pressure-sensitive adhesive. Suitable adhesives include,for example, Century A-305-IV manufactured by the Century AdhesivesCorporation of Columbus, Ohio; and Instant Lock 34-2823 manufactured bythe National Starch and Chemical Company of Bridgewater, N.J. Suitableadhesive fasteners are also described in U.S. Pat. No. 4,917,697. Beforethe absorbent article is placed in use, the pressure-sensitive adhesiveis typically covered with a removable release liner in order to keep theadhesive from drying out or adhering to a surface other than the crotchportion of the panty prior to use. Suitable release liners are alsodescribed in U.S. Pat. Nos. 4,917,697 and 4,556,146. Any commerciallyavailable release liners commonly used for such purposes can be utilizedherein. Non-limiting examples of suitable release liners are BL30MG-ASilox E1/0 and BL30MG-A Silox 4P/O both of which are manufactured by theAkrosil Corporation of Menasha, Wis. The pad can be used by removing therelease liner and thereafter placing the absorbent article in a panty sothat the adhesive contacts the panty. The adhesive maintains theabsorbent article in its position within the panty during use. Therelease liner can also be a wrapper that can individually package thepad.

Again, although the majority of discussion herein is around incontinencepads and sanitary napkins, it is envisioned that this invention is alsouseful for taped diapers, training pants which pull on, adultincontinence diapers and pants, and replaceable pads for incontinenceand menses collection that might be inserted and removed after use in adisposable or durable panty or underpant.

Test Methods Article Length Method

The overall length of an absorbent article is measured as the distancebetween a front leading edge of a pad and a rear leading edge of a pad,along the longitudinal centerline. Measurements are made using acalibrated steel metal ruler traceable to NIST, or equivalent. Testsamples are conditioned at 23° C.±2 C.° and 50%±2% relative humidity for2 hours prior to testing and all testing is performed under these sameenvironmental conditions.

Remove the test sample from its wrapper and if present, remove therelease paper to expose the panty fastening adhesive (PFA). Apply talcpowder to the PFA on the back sheet to mitigate tackiness. Suspend thearticle vertically by its front leading edge. Attach a 500 g±1 g weightto the rear leading edge allowing the article to hang freely. After 30sec measure the length of the article along the longitudinal centerlineof the article to the nearest 1 mm and record as the Article Length(AL). In like fashion, repeat for a total of at least four replicatetest samples. Calculate the arithmetic mean and report to the nearest 1mm.

Pad Thickness Method

The thickness of an absorbent article is measured as the distancebetween a reference platform on which the absorbent article rests and apressure foot that exerts a specified amount of pressure onto thearticle over a specified amount of time. Pad thickness can be measuredas single product stack height and caliper of individual unwrapped pads.All measurements are performed in a laboratory maintained at 23° C.±2C.° and 50%±2% relative humidity.

Pad thickness is measured with a manually-operated micrometer equippedwith a pressure foot capable of exerting a steady pressure of 0.88 kPaonto the test sample. The manually-operated micrometer is a dead-weighttype instrument with readings accurate to 0.001 mm. A suitableinstrument is Mitutoyo Series 543 ID-C Digimatic, available from VWRInternational, or equivalent. The pressure foot is a flat groundcircular movable face with a diameter of 40 mm. The test sample issupported by a horizontal flat reference platform that is larger thanand parallel to the surface of the pressure foot. The system iscalibrated and operated per the manufacturer's instructions.

Test samples are removed from their outermost packaging (e.g., polybag)and conditioned in a room maintained at 23° C.±2 C.° and 50%±2% relativehumidity for at least 2 hours prior to testing. To measure singleproduct stack height, thickness measurements are made on pads thatremain folded inside any wrapper that is present. The test location isdefined as the longitudinal and lateral midpoint of the test sample inits wrapper. Zero the micrometer against the horizontal flat referenceplatform. Place the test sample on the platform with the test locationcentered below the pressure foot. Orient the test sample so that anyexposed or fastened edge of the wrapper faces the platform, not thepressure foot. Gently lower the pressure foot with a descent rate of 0.8mm±0.1 mm per second until the full pressure is exerted onto the testsample. Wait 5 seconds and then record the thickness of the test sampleto the nearest 0.01 mm. In like fashion, repeat for a total of at leastfour replicate test samples. Calculate the arithmetic mean for theSingle Product Stack Height and report to the nearest 0.01 mm.

To measure the caliper of the individual unwrapped pad, remove the testsample from its wrapper. If folded, gently unfold it and smooth out anywrinkles. If present, remove the release paper to expose the pantyfastening adhesive (PFA). Apply talc powder to the PFA on the back sheetto mitigate tackiness. The test location is defined as the longitudinaland lateral midpoint of the test sample's absorbent core. Proceed withthe thickness measurement as previously stated, orienting the topsheetside of the test sample towards the pressure foot. In like fashion,repeat for a total of at least four replicate test samples. Calculatethe arithmetic mean for the Pad Thickness and report to the nearest 0.01mm.

Speed of Acquisition with Balloon Applied Pressure Method & Rewet Method

The SABAP (Speed of Acquisition with Balloon Applied Pressure) testmethod is designed to measure the speed at which a known volume of 0.9%saline solution is absorbed into an absorbent article which iscompressed at 1.7 kPa. Time needed to absorb the dose is recorded.Subsequent to the acquisition test, PACORM (Post Acquisition CollagenRewet Method) is performed. The test comprises measuring the mass offluid expressed from the article under pressure after loading by theSABAP protocol. Collagen sheets are used as the rewet substrate. Asuitable collagen is Naturin Coffi collagen sheets (available fromViscofan USA Inc., 50 Country Court, Montgomery, Ala. 36105, USA) orequivalent. Upon receipt, the collagen sheets are stored at about 23°C.±2 C.° and about 50%±2 relative humidity. All testing is performed ina room also maintained at about 23° C.±2 C.° and about 50%±2% relativehumidity.

The SABAP apparatus is depicted in FIG. 6 and FIG. 7. It consists of abladder assembly 1001 and a top plate assembly 1200 which includes thedeposition assembly 1100. A controller 1005 is used to 1) monitor theimpedance across the electrodes 1106, recording the time interval 0.9%saline solution is in the cylinder 1102, 2) interface with the liquidpump 1004 to start/stop dispensing, and 3) time intervals betweendosing. The controller is capable of recording time events to ±0.01 sec.A house air supply 1014 is connected to the pressure regulator 1006capable of delivering air at a suitable flow/pressure to maintain 1.7kPa in the bladder assembly. A liquid pump 1004 (Ismatec MCP-Z gearpump, available from Cole Palmer, Vernon Hills, Ill. or equivalent)capable of delivering a flow of 2-120 mL at a rate of 2-20 mL/s isattached to the steel tube 1104 of the deposition assembly 1100 viaTygon® tubing 1015.

The bladder assembly 1001 is constructed of 12.7 mm Plexiglas® with anoverall dimension of 80 cm long by 30 cm wide by 5 cm tall. A manometer1007 to measure the pressure inside the assembly and a pressure gauge1006 to regulate the introduction of air into the assembly are installedthrough two holes through the right side. The bladder 1013 is assembledby draping a 50 mm by 100 mm piece of silicone film, (thickness 0.02″,Shore A durometer value of 20, available as Part #86435K85 fromMcMaster-Carr, Cleveland, Ohio) over the top of the box with enoughslack that the latex touches the bottom of the box at its center point.An aluminum frame 1003 with a flange is fitted over the top of the latexand secured in place using mechanical clamps 1010. When in place theassembly should be leak free at a pressure of 3.45 kPa. A front 1008 andback 1009 sample support 5 cm by 30 cm by 1 mm are used to anchor thesample. The article is attached to the top surface of the samplesupports by either adhesive tape or mechanical “hook” fasteners. Thesesupports can be adjusted along the length of the aluminum frame 1003 viaa simple pin and hole system to accommodate different size absorbentarticles and to correctly align their loading point.

The top plate assembly 1200 is constructed of an 80 cm by 30 cm piece of12.7 mm Plexiglas® reinforced with an aluminum frame 1109 to enhancerigidity. The deposition assembly 1100 is centered 30 cm (1201) from thefront of the plate assembly and 15 cm (1203) from either side. Thedeposition assembly is constructed of a 50.8 mm O.D. Plexiglas® cylinder1102 with a 38.1 mm I.D. The cylinder is 100 mm tall and is insertedthrough the top plate 1101 and flush with the bottom of the plate 1101.Two electrodes 1106 are inserted though the top plate and cylinder andexit flush with the inner wall of the cylinder immediately above thecylinders bottom surface. A nylon screen 1107 cut into two semicirclesare affixed flush with the bottom of the cylinder such that the samplecannot swell into the cylinder. The cylinder is topped with aloose-fitting nylon cap 1103. The cap has a 6.35 mm O.D. steel tube 1104inserted through its center. When the cap is in place, the bottom of thetube ends 20 mm above (1108) the screen 1107. The cap also has an airhole 1105 to ensure negative pressure does not impede the absorptionspeed. In addition, the top plate has forty-four (44) 3.2 mm diameterholes drilled through it distributed as shown in FIG. 7. The holes areintended to prevent air from being trapped under the top plate as thebladder is inflated but not to allow fluid to escape. The top plateassembly 1200 is connected to the bladder assembly 1001 via two hinges1012. During use the top assembly is closed onto the bladder assemblyand locked into place using a mechanical clamp 1011.

The PACORM equipment consist of a Plexiglas® disk 60.0 mm in diameterand 20 mm thick and a confining weight that rests upon it. The mass ofthe disk and confining weight combined is 2000 g±2 g, equivalent to 6.9kPa of pressure. Collagen is die cut into 90.0 mm circles and stacks offour (4) assembled for use during rewet testing. Measure and record themass of the dry collagen stack and record to the nearest 0.0001 g.

Samples are conditioned at 23° C.±2 C.° and about 50%±2% relativehumidity for two hours prior to testing. The article is first preparedby excising any inner or outer leg cuffs, waist caps, elastic ears orside panels if present, taking care not to disturb the top sheet thatresides above the article's core region. Place the article flat onto alab bench and identifying the intersection of the longitudinal andlateral centerlines of the article.

Attach the front end of the article to the top surface of the frontsample plate 1008 by either adhesive tape or mechanical “hook” fastenerswith the top sheet facing upward. The placement is such that just thechassis and not the absorptive core overlays the plate. The sample plate1008 is attached to the aluminum frame 1003 such that the article'sabsorbent core will be centered longitudinally and laterally within thecylinder 1102 when the top plate assembly has been closed. The back endof the article is secured to the back sample plate 1009 by eitheradhesive tape or mechanical “hook” fasteners, once again ensuring thatonly the chassis and not the absorptive core overlays the plate. Theback sample plate 1009 is then attached to the aluminum frame 1003 suchthat the article is taunt but not stretched. The top plate assembly isclosed and fastened, and the bladder is inflated to 1.7 kPa.

A 0.9% w/v saline solution is prepared by weighing 9.0 g±0.05 g of NaClinto a weigh boat, transferring it into a 1 L volumetric flask anddiluting to volume with de-ionized water. The pump 1004 is primed thencalibrated to deliver each size dependent volume and flow rate asdefined in Table 2.

TABLE 2 Size Dependent Volumes and Flow Rates for Acquisition TestingArticle Length Volume Rate (mm) (mL) (mL/sec) 250-329 20.0 5 330-37040.0 10 >370 60.0 15

Volume and flow rate must be within ±2% of target. The cap 1103 isplaced into the cylinder 1102. The controller 1005 is started, which inturn delivers the prescribed dose of 0.9% saline solution. If the fluidleaks out of or around the product (i.e., is not absorbed into thearticle) then the test is aborted. Also, if any acquisition time exceeds1200 sec, the test is aborted. Acquisition times are recorded by thecontroller to the nearest 0.01 sec.

Five minutes after the test is complete (i.e., the dose has beenabsorbed), the pressure relief valve 1016 is opened to deflate thebladder and the sample article removed from the bladder system forPACORM (Post Acquisition Collagen Rewet Method) evaluation.

Within 30 sec, place the specimen flat on a bench top, place apre-weighed stack of collagen centered at the longitudinal and lateralmidpoint of the article's absorbent core, place a Plexiglas® diskcentered onto the collagen stack, and gently place confining weight ontothe disk. Wait for 30.0 sec±0.5 sec and remove the weight. Immediatelymeasure the mass of the wet collagen and record to the nearest 0.0001 g.Calculate the rewet value as the difference between the wet and dryweight of the stack and record to the nearest 0.0001 g.

In like fashion, run a total of at least five (5) replicates for eacharticle to be evaluated. Calculate and report the Acquisition Time asthe arithmetic mean to the nearest 0.01 seconds. Calculate the Rewet forthe at least five replicates as the arithmetic mean to the nearest0.0001 g.

Bunch Compression Test Method

Bunched Compression of a sample is measured on a constant rate ofextension tensile tester (a suitable instrument is the MTS Allianceusing Testworks 4.0 software, as available from MTS systems Corp., EdenPrairie, Minn., or equivalent) using a load cell for which the forcesmeasured are within 10% to 90% of the limit of the cell. All testing isperformed in a room controlled at 23° C.±3C° and 50%±2% relativehumidity. The test can be performed wet or dry.

In FIG. 8, the bottom stationary fixture 3000 consists of two matchingsample clamps 3001 each 100 mm wide each mounted on its own movableplatform 3002 a, 3002 b. The clamp has a “knife edge” 3009 that is 110mm long, which clamps against a 1 mm thick hard rubber face 3008. Whenclosed, the clamps are flush with the interior side of its respectiveplatform. The clamps are aligned such that they hold an un-bunchedspecimen horizontal and orthogonal to the pull axis of the tensiletester. The platforms are mounted on a rail 3003 which allows them to bemoved horizontally left to right and locked into position. The rail hasan adapter 3004 compatible with the mount of the tensile tester capableof securing the platform horizontally and orthogonal to the pull axis ofthe tensile tester. The upper fixture 2000 is a cylindrical plunger 2001having an overall length of 70 mm with a diameter of 25.0 mm. Thecontact surface 2002 is flat with no curvature. The plunger 2001 has anadapter 2003 compatible with the mount on the load cell capable ofsecuring the plunger orthogonal to the pull axis of the tensile tester.

Samples are conditioned at 23° C.±3C° and 50%±2% relative humidity forat least 2 hours before testing. When testing a whole article, removethe release paper from any panty fastening adhesive on the garmentfacing side of the article. Lightly apply talc powder to the adhesive tomitigate any tackiness. If there are cuffs, excise them with scissors,taking care not to disturb the top sheet of the product. Place thearticle, body facing surface up, on a bench. On the article identify theintersection of the longitudinal midline and the lateral midline. Usinga rectangular cutting die, cut a specimen 100 mm in the longitudinaldirection by 80 mm in the lateral direction, centered at theintersection of the midlines. When testing just the absorbent body of anarticle, place the absorbent body on a bench and orient as it will beintegrated into an article, i.e., identify the body facing surface andthe lateral and longitudinal axis. Using a rectangular cutting die, cuta specimen 100 mm in the longitudinal direction by 80 mm in the lateraldirection, centered at the intersection of the midlines. The specimencan be analyzed both wet and dry. The dry specimen requires no furtherpreparation. The wet specimens are dosed with 0.9% w/v saline solution(i.e., 9.0 g of NaCl diluted to 1 L deionized water). The volume ofliquid added to the specimen is determined by the overall length of thepad being tested, according to Table 3 below.

TABLE 3 Article Volume Length of Dose (mm) (mL) 250-329 10.00 ± 0.01330-370 20.00 ± 0.01 >370 30.00 ± 0.01

The dose is added using a calibrated Eppendorf-type pipettor, spreadingthe fluid over the complete body facing surface of the specimen within aperiod of approximately 3 sec. The wet specimen is tested 10.0 min±0.1min after the dose is applied.

Program the tensile tester to zero the load cell, then lower the upperfixture at 2.00 mm/sec until the contact surface of the plunger touchesthe specimen and 0.02 N is read at the load cell. Zero the crosshead.Program the system to lower the crosshead 15.00 mm at 2.00 mm/sec thenimmediately raise the crosshead 15.00 mm at 2.00 mm/sec. This cycle isrepeated for a total of five cycles, with no delay between cycles. Datais collected at 100 Hz during all compression/decompression cycles.

Position the left platform 3002 a 2.5 mm from the side of the upperplunger (distance 3005). Lock the left platform into place. Thisplatform 3002 a will remain stationary throughout the experiment. Alignthe right platform 3002 b 60.0 mm from the stationary clamp (distance3006). Raise the upper probe 2001 such that it will not interfere withloading the specimen. Open both clamps. Referring to FIG. 9a , place thespecimen with its longitudinal edges (i.e., the 100 mm long edges)within the clamps. With the specimen laterally centered, securely fastenboth edges. Referring to FIG. 9b , move the right platform 3002 b towardthe stationary platform 3002 a a distance 20.0 mm. Allow the specimen tobow upward as the movable platform is positioned. Manually lower theprobe 2001 until the bottom surface is approximately 1 cm above the topof the bowed specimen.

Start the test and collect displacement (mm) verses force (N) data forall five cycles. Construct a graph of Force (N) versus displacement (mm)separately for all cycles. A representative curve is shown in FIG. 10a .From the curve record the Maximum Compression Force for each Cycle tothe nearest 0.01N. Calculate the % Recovery between the First and Secondcycle as (TD-E2)/(TD-E1)*100 where TD is the total displacement and E2is the extension on the second compression curve that exceeds 0.02 N.Record to the nearest 0.01%. In like fashion calculate the % Recoverybetween the First Cycle and other cycles as (TD-E1)/(TD-E1)*100 andreport to the nearest 0.01%. Referring to FIG. 10b , calculate theEnergy of Compression for Cycle 1 as the area under the compressioncurve (i.e., area A+B) and record to the nearest 0.1 mJ. Calculate theEnergy Loss from Cycle 1 as the area between the compression anddecompression curves (i.e., Area A) and report to the nearest 0.1 mJ.Calculate the Energy of Recovery for Cycle 1 as the area under thedecompression curve (i.e. Area B) and report to the nearest 0.1 mJ. Inlike fashion, calculate the Energy of Compression (mJ), Energy Loss (mJ)and Energy of Recovery (mJ) for each of the other cycles and record tothe nearest 0.1 mJ. For each sample, analyze a total of five (5)replicates and report the arithmetic mean for each parameter. Allresults are reported as positive numbers and specifically as dry or wetincluding the volume of the dose.

Examples—Part A

-   A. An absorbent article comprising:    -   a. a primary topsheet having a body-facing surface and a        garment-facing surface;    -   b. a backsheet having a body-facing surface and garment-facing        surface;    -   c. an absorbent core having a front end portion, a central        portion, and a rear end portion along its length, said core        being disposed between said primary topsheet garment-facing        surface and said backsheet body-facing surface, and    -   wherein said article exhibits an article length of from about        371 mm to about 500 mm according to the Article Length Method;        an Acquisition Time for a load of 60 ml of less than about 39        seconds according to a Speed of Acquisition with Balloon Applied        Pressure Method; a dry pad thickness of between about 4.6 mm to        about 12 mm according to a Pad Thickness Method; and an Energy        of Recovery at a load of 30 ml of from about 5 mJ to about 11 mJ        according to a Bunch Compression Method.-   B. The absorbent article of paragraph A wherein said article    exhibits an Acquisition Time for a load of 60 ml of less than about    37 seconds according to the Speed of Acquisition with Balloon    Applied Pressure Method.-   C. The absorbent article of paragraph B wherein said article    exhibits an Acquisition Time for a load of 60 ml of less than about    35 seconds according to the Speed of Acquisition with Balloon    Applied Pressure Method.-   D. The absorbent article of paragraph A wherein said article    exhibits a dry pad thickness of between about 4.8 mm to about 10 mm    according to a Pad Thickness Method.-   E. The absorbent article of any one of paragraph A to D wherein said    article exhibits an Energy of Recovery at a load of 30 ml of from    about 4.8 mJ to about 10 mJ according to a Bunch Compression Method.-   F. The absorbent article of any one of paragraphs A to E wherein    said core comprises a) a first laminate which includes a first    superabsorbent layer disposed onto a first distribution layer and b)    a second laminate which includes a second distribution layer joined    to a second superabsorbent layer; wherein said first distribution    layer is joined to said second distribution layer.-   G. The absorbent article of paragraph F wherein said first    distribution layer is joined to said second distribution layer in an    offset manner along a length of the core such that said central    portion of said core is formed from an overlapping joinder of said    first and second laminates.-   H. The absorbent article of any one of paragraphs A to G wherein    said front end portion and said rear end portion are respectively    disposed at opposing ends of said central portion of said core.-   I. The absorbent article of any one of paragraphs A to H wherein    said first and second superabsorbent layers have different cross    direction widths from one another.-   J. The absorbent article of paragraph I wherein said first    superabsorbent layer has a lesser cross-direction width than said    second superabsorbent layer.-   K. The absorbent article of paragraph I wherein each of said first    and second superabsorbent layers span greater than 50% of the    cross-direction width of the respective adjoining first or second    distribution layer.-   L. The absorbent article of any one of paragraphs A to K wherein    said first or second superabsorbent layers are substantially free of    airfelt.-   M. The absorbent article of any one of paragraphs A to L wherein    said first superabsorbent layer is disposed discontinuously onto the    first distribution layer.-   N. The absorbent article of any one of paragraphs A to M wherein    said second superabsorbent layer is disposed in a continuous    pattern.-   O. The absorbent article of any one of paragraphs A to N wherein    said first and second laminates have cross-direction widths that are    the same.-   P. The absorbent article of any one of paragraphs A to O wherein    said first and second laminates have cross-direction widths that are    different.-   Q. The absorbent article of any one of paragraphs A to P wherein    said first and second laminates have machine-direction lengths that    are the same.-   R. The absorbent article of any one of paragraphs A to Q wherein    said first and second laminates have machine-direction lengths that    are different.-   S. The absorbent article of any one of paragraphs A to R wherein    said first and second distribution layers each comprise an airlaid    material.-   T. The absorbent article of any one of paragraphs A to S wherein    said first and second laminates each have a first end that is    complementary in shape to a respective second end of the same    laminate.-   U. An absorbent article comprising a chassis which comprises:    -   a. a primary topsheet having a body-facing surface and a        garment-facing surface;    -   b. a backsheet having a body-facing surface and garment-facing        surface;    -   c. an absorbent core which is disposed between said primary        topsheet garment-facing surface and said backsheet body-facing        surface and wherein said core further comprises a first laminate        having a first end which is complementary in shape to a        respective second end, said first laminate comprises a first        superabsorbent layer disposed onto a first distribution layer;    -   wherein said article exhibits an article length of from about        371 mm to about 500 mm according to the Article Length Method;        an Acquisition Time for a load of 60 ml of less than about 39        seconds according to a Speed of Acquisition with Balloon Applied        Pressure Method; a dry pad thickness of between about 4.6 mm to        about 12 mm according to a Pad Thickness Method; and an Energy        of Recovery at a load of 30 ml of from about 5 mJ to about 11 mJ        according to a Bunch Compression Method.-   V. The absorbent article of paragraph W wherein said core further    comprises a second laminate having a first end which is    complementary in shape to its respective second end and wherein said    second laminate includes a second distribution layer joined to a    second superabsorbent layer; wherein said first distribution layer    is joined to said second distribution layer in an offset manner    along a length of the absorbent article wherein the absorbent core    has a front end portion that is formed by the first end of the    second laminate.-   W. An absorbent article comprising a chassis which comprises:    -   a. a primary topsheet having a body-facing surface and a        garment-facing surface;    -   b. a backsheet having a body-facing surface and garment-facing        surface;    -   c. an absorbent core which is disposed between said primary        topsheet garment-facing surface and said backsheet body-facing        surface, wherein said core comprises        -   1) a first laminate which includes a first superabsorbent            layer disposed onto a first distribution layer and        -   2) a second laminate which includes a second distribution            layer joined to a second superabsorbent layer; wherein said            first distribution layer is joined to said second            distribution layer along a length of the absorbent article            wherein either of the first or second laminates has a larger            cross-direction width than the other and    -   wherein said article exhibits an article length of from about        371 mm to about 500 mm according to the Article Length Method;        an Acquisition Time for a load of 60 ml of less than about 39        seconds according to a Speed of Acquisition with Balloon Applied        Pressure Method; a dry pad thickness of between about 4.6 mm to        about 12 mm according to a Pad Thickness Method; and an Energy        of Recovery at a load of 30 ml of from about 5 mJ to about 11 mJ        according to a Bunch Compression Method.-   X. An absorbent article comprising a chassis which comprises:    -   a. a primary topsheet having a body-facing surface and a        garment-facing surface;    -   b. a backsheet having a body-facing surface and garment-facing        surface;    -   c. an absorbent core which is disposed between said primary        topsheet garment-facing surface and said backsheet body-facing        surface, wherein said core comprises a first laminate which        includes a first superabsorbent layer disposed discontinuously        onto a first distribution layer and a second laminate which        includes a second distribution layer joined to a second        superabsorbent layer; wherein said first distribution layer is        joined to said second distribution layer; and    -   wherein said article exhibits an article length of from about        371 mm to about 500 mm according to the Article Length Method;        an Acquisition Time for a load of 60 ml of less than about 39        seconds according to a Speed of Acquisition with Balloon Applied        Pressure Method; a dry pad thickness of between about 4.6 mm to        about 12 mm according to a Pad Thickness Method; and an Energy        of Recovery at a load of 30 ml of from about 5 mJ to about 11 mJ        according to a Bunch Compression Method.-   Y. The absorbent article of claim 24 wherein said first and second    laminates are joined to one another in an offset manner via their    respective distribution layers.

Examples—Part B

Examples 1 and 2 are constructed in accordance with the presentdisclosure.

Example 1

An incontinence pad or sanitary napkin approximately 400 mm long havingan hourglass shape is constructed. It has a maximum width of 119 mm anda width of 98 mm in the center of the length. The product has 2 foldlines along its length. The layers are adhesively combined usingappropriate hotmelt adhesives known in the art. The outer perimeter iscrimped (via heat and pressure). The pad includes the followingcomponents:

1) Primary topsheet comprising 18 gsm PE/PP bico (Sheath/core) nonwovenwith hydrophilic surfactant treatment and a printed quilted pattern.2) Secondary topsheet which is continuous in MD and 79 mm wide in the CDand formed from a material of 45% hollow, spiral PET fibers (10 dtex, 38mm staple length), 30% Sheath/Core PE/PET Bico Fibers (5.8 dtex), 25%tri-lobal rayon fibers (3.3 dtex).3) Absorbent core which includes at least the following two laminates.

-   -   a) First laminate is 59 mm wide×310 mm long (on a longitudinal        axis or centerline). All layers of the laminate are this full        length. The first end of the first laminate exhibits nested        cutting with a radius of 51.6 mm in a male connection shape        complementing the shape of the second end of the same laminate        which is a female connection. Hence, the first and second ends        mate with one another. The first superabsorbent layer is formed        from an AGM carrier material of 10 gsm SMS PP nonwoven (59 mm        wide) and a layer of superabsorbent particles (AGM) which is 59        mm wide with AGM free areas approximately 10 mm square arranged        throughout the first laminate are formed where a total of 4.55 g        total AGM is utilized thereon. The first superabsorbent layer is        joined to an airlaid material (135 gsm) comprised of pulp        (82.5%), bico fiber (15%) and latex (2.5%) at 59 mm wide.    -   b) A second laminate is 79 mm wide×310 mm long on a longitudinal        axis or centerline. The first end of the second laminate        exhibits nested cutting with a radius of 51.6 mm in a male        connection shape and complementing the female connection shape        of the second end of the same laminate. The second distribution        layer comprises an airlaid material (135 gsm) comprised of pulp        (82.5%), bico fiber (15%) and latex (2.5%) at 79 mm wide. The        second superabsorbent layer comprise an AGM carrier material of        10 gsm SMS PP nonwoven which is 79 mm wide and thereon is        disposed a layer of superabsorbent particles (AGM) at 71 mm wide        in a continuous pattern in the MD and CD with a total of 5.7 g        of AGM.

The first and second laminates are arranged with the distribution layerscontacting and joined with opposing first ends of each laminate whichhave male connection or convex shapes forming the respective ends of theresultant pad. This pad has a total length from a front end portion to arear end portion along the longitudinal axis of 381 mm.

4) A backsheet comprises a 14 gsm polypropylene film.5) A barrier cuff nonwoven first cover/second cover each having a basisweight of 15 gsm (glue continuously in MD to the topsheet with a spacingof 72 mm and glued intermittently for about 87 mm at the ends of theproduct with a 60 mm spacing) and having an inner to inner spacing ofabout 54 mm (continuing to CD edges);6) Barrier cuff elastic members or strands are formed from Lycra®. Thereare 2 strands per cuff each having 470 dtex stretched about 80% each andglued for 195 mm (attachment approximately 113 mm from leading and 93 mmfrom trailing edge). Inner to inner elastic spacing of about 61 mm andspacing of about 4 mm between each strand in each cuff.

Example 2

An incontinence pad or sanitary napkin approximately 400 mm long havingan hourglass shape is constructed. It has a maximum width of 119 mm anda width of 98 mm in the center of the length. The product has 2 foldlines along its length. The layers are adhesively combined usingappropriate hotmelt adhesives known in the art. The outer perimeter iscrimped (via heat and pressure). The pad includes the followingcomponents:

1) Primary topsheet comprising 18 gsm PE/PP bico (Sheath/core) nonwovenwith hydrophilic surfactant treatment and a printed quilted pattern.2) Secondary topsheet which is continuous in MD and 79 mm wide in the CDand formed from a material of 45% hollow, spiral PET fibers (10 dtex, 38mm staple length), 30% Sheath/Core PE/PET Bico Fibers (5.8 dtex), 25%tri-lobal rayon fibers (3.3 dtex).3) Absorbent core which includes at least the following two laminates.

-   -   a) First laminate is 50.5 mm wide×339 mm long (on a longitudinal        axis or centerline). All layers of the laminate are this full        length. The first end of the first laminate exhibits nested        cutting with a radius of 46.5 mm in a male connection shape        complementing the shape of the second end of the same laminate        which is a female connection. Hence, the first and second ends        mate with one another. The first superabsorbent layer is formed        from an AGM carrier material of 10 gsm SMS PP nonwoven 61.5 mm        wide (including 11 mm wrapped around the airlaid material on one        side) and a layer of superabsorbent particles (AGM) which is        38.5 mm wide with AGM free areas approximately 10 mm square        arranged throughout the first laminate are formed where a total        of 2.84 g total AGM is utilized thereon. The first        superabsorbent layer is joined to an airlaid material (160 gsm)        comprised of pulp (82.5%), bico fiber (15%) and latex (2.5%) at        50.5 mm wide.    -   b) A second laminate is 77.5 mm wide×339 mm long on a        longitudinal axis or centerline. The first end of the second        laminate exhibits nested cutting with a radius of 51.6 mm in a        male connection shape and complementing the female connection        shape of the second end of the same laminate. The second        distribution layer comprises an airlaid material (160 gsm)        comprised of pulp (82.5%), bico fiber (15%) and latex (2.5%) at        77.5 mm wide. The second superabsorbent layer comprise an AGM        carrier material of 10 gsm SMS PP nonwoven which is 88.5 mm wide        (including 11 mm material wrapped around back side of airlaid        material) and thereon is disposed a layer of superabsorbent        particles (AGM) at 65.5 mm wide in a continuous pattern in the        MD and CD with a total of 6.09 g of AGM.

The first and second laminates are arranged with the distribution layerscontacting and joined with opposing first ends of each laminate whichhave male connection or convex shapes forming the respective ends of theresultant pad. This pad has a total length from a front end portion to arear end portion along the longitudinal axis of 381 mm.

4) A backsheet comprises a 14 gsm polypropylene film.5) A barrier cuff nonwoven first cover/second cover each having a basisweight of 15 gsm (glue continuously in MD to the topsheet with a spacingof 72 mm and glued intermittently for about 87 mm at the ends of theproduct with a 60 mm spacing) and having an inner to inner spacing ofabout 54 mm (continuing to CD edges);6) Barrier cuff elastic members or strands are formed from Lycra®. Thereare 2 strands per cuff each having 470 dtex stretched about 80% each andglued for 195 mm (attachment approximately 113 mm from leading and 93 mmfrom trailing edge). Inner to inner elastic spacing of about 61 mm andspacing of about 4 mm between each strand in each cuff.

The article of Examples 1 and 2 are compared to commercially availableproducts in terms of the physical properties mentioned earlier in Table4.

TABLE 4 Acquisition Time vs. Load Always Poise Tena Example ExampleDiscreet Pads Serenity 1 2 Acq Time at 60 ml (s) 39.08 19.18 17.64 34.2424.82 Pad Thickness 4.44 13.00 13.75 6.42 6.89 (Dry, Unwrapped singlepad) (mm) Energy of Recovery 6.2 10.5 4.9 5.2 4.5 at 20 ml (mJ) Energyof Recovery, 4.3 12.3 4.3 9.4 9.6 Dry (mJ)

The above comparative pads are detailed below.

1. Poise Pads—Poise Overnight Pads: Ultimate Absorbency Long Length 2.Tena Serenity—Tena Serenity: Overnight Pads 3. Always Discreet—AlwaysDiscreet: Pads Ultimate Long Length

It is evident that the Examples of the present invention possess thevarious claimed physical property combinations as opposed to thecommercially available incontinence products. As such, those of thepresently claimed articles are able to deliver the performance,discretion, and resilience benefits as captured by the claimedcharacteristics whereas the commercial products are not.

What is claimed is:
 1. An absorbent article comprising: a. a primarytopsheet having a body-facing surface and a garment-facing surface; b. abacksheet having a body-facing surface and garment-facing surface; c. anabsorbent core having a front end portion, a central portion, and a rearend portion along its length, said core being disposed between saidprimary topsheet garment-facing surface and said backsheet body-facingsurface, and wherein said article exhibits an article length of fromabout 371 mm to about 500 mm according to the Article Length Method; adry pad thickness of between about 4.6 mm to about 12 mm according to aPad Thickness Method; and an Energy of Recovery at a load of 30 ml offrom about 4 mJ to about 11 mJ according to a Bunch Compression Method.2. The absorbent article of claim 1 wherein said article exhibits anAcquisition Time for a load of 60 ml of less than about 37 secondsaccording to the Speed of Acquisition with Balloon Applied PressureMethod.
 3. The absorbent article of claim 2 wherein said articleexhibits an Acquisition Time for a load of 60 ml of less than about 35seconds according to the Speed of Acquisition with Balloon AppliedPressure Method.
 4. The absorbent article of claim 1 wherein saidarticle exhibits a dry pad thickness of between about 4.8 mm to about 10mm according to a Pad Thickness Method.
 5. The absorbent article ofclaim 1 wherein said article exhibits an Energy of Recovery at a load of30 ml of from about 4.3 mJ to about 10 mJ according to a BunchCompression Method.
 6. The absorbent article of claim 1 wherein saidcore comprises a) a first laminate which includes a first superabsorbentlayer disposed onto a first distribution layer and b) a second laminatewhich includes a second distribution layer joined to a secondsuperabsorbent layer; wherein said first distribution layer is joined tosaid second distribution layer.
 7. The absorbent article of claim 6wherein said first distribution layer is joined to said seconddistribution layer in an offset manner along a length of the core suchthat said central portion of said core is formed from an overlappingjoinder of said first and second laminates.
 8. The absorbent article ofclaim 1 wherein said front end portion and said rear end portion arerespectively disposed at opposing ends of said central portion of saidcore.
 9. The absorbent article of claim 6 wherein said first and secondsuperabsorbent layers have different cross direction widths from oneanother.
 10. The absorbent article of claim 9 wherein said firstsuperabsorbent layer has a lesser cross-direction width than said secondsuperabsorbent layer.
 11. The absorbent article of claim 6 wherein eachof said first and second superabsorbent layers span greater than 50% ofthe cross-direction width of the respective adjoining first or seconddistribution layer.
 12. The absorbent article of claim 6 wherein saidfirst or second superabsorbent layers are substantially free of airfelt.13. The absorbent article of claim 6 wherein said first superabsorbentlayer is disposed discontinuously onto the first distribution layer. 14.The absorbent article of claim 6 wherein said second superabsorbentlayer is disposed in a continuous pattern.
 15. The absorbent article ofclaim 6 wherein said first and second laminates have cross-directionwidths that are the same.
 16. The absorbent article of claim 6 whereinsaid first and second laminates have cross-direction widths that aredifferent.
 17. The absorbent article of claim 6 wherein said first andsecond laminates have machine-direction lengths that are the same. 18.The absorbent article of claim 6 wherein said first and second laminateshave machine-direction lengths that are different.
 19. The absorbentarticle of claim 6 wherein said first and second distribution layerseach comprise an airlaid material.
 20. The absorbent article of claim 6wherein said first and second laminates each have a first end that iscomplementary in shape to a respective second end of the same laminate.